Shape-formable apparatus comprising fibrous material

ABSTRACT

A shape-formable apparatus comprising fibrous material. The apparatus can have a first state in which the apparatus is formable into a desired shape, and a second state in which the apparatus has the desired shape and is substantially less formable than in the first state. The apparatus can include an envelope defining a chamber, a port positioned to fluidly couple the chamber with ambience, and a fibrous material positioned in the chamber. The fibrous material can be substantially less formable when the apparatus is in the second state than when the apparatus is in the first state.

FIELD

The present disclosure generally relates to shape-formable apparatusesthat are configured to be formed into a desired shape and then held inthe desired shape, and particularly, to shape-formable apparatusescomprising fibrous material.

BACKGROUND

A variety of applications could benefit from a material or device havinga stiffness that can change from a first (flexible) state, in which thematerial is shape-formable to a desired shape, to a second (more rigid)state, in which the desired shape can be held or fixed.

Some existing shape-formable devices employ discrete particles (i.e.,bulk media) in a gas impermeable envelope that normally move freely withrespect to one another, but “jam” together and resist relative motionwhen the internal pressure of the envelope is reduced below ambientpressure. This jamming of bulk media has been proposed for a variety ofproducts, from a medical restraint for babies (U.S. Pat. No. 4,885,811)to limb demobilization (U.S. Pat. No. 4,657,003), to the stabilizationof patients during surgery (U.S. Pat. No. 6,308,353), to robotic endeffectors (U.S. Publication No. 2010/0054903). One significantdisadvantage of bulk media jamming is the significant volume requiredfor a bulk media-filled device. The bulk media does not lend itself wellto thin, sheet-like, applications.

Other existing devices or systems employ bending stiffness variation ina thin form factor. By putting sheets of material in an envelope andremoving air from the envelope (e.g., as in U.S. Publication No.2012/0310126 and Ou et al., “jamSheets: Thin Interfaces with TunableStiffness Enabled by Layer Jamming,” TEI '14 Proceedings of the 8thInternational Conference on Tangible, Embedded and Embodied Interaction,pages 65-72, Association for Computing Machinery (ACM), February 2014),a relatively thin article can be achieved with a variable bendingstiffness. They achieve a low bending stiffness in an unjammed state,despite having a high Young's Modulus (or tensile modulus), by allowingmultiple thin layers of material to slide over each other. However,because these individual layers each have a high overall Young'sModulus, even in an unjammed state, and they are substantiallycontinuous in one or more axes within the plane, they cannot be easilyextended within the plane, or major surface, of the thin article.Because the individual layers lack this extensibility, theconformability of the layers is also limited. Thus, these layers canonly take on complex shapes by generating wrinkles, and not by smoothlyand continuously assuming arbitrary shapes. The bending stiffness ofthese systems can increase under vacuum, because the multiple layers jamtogether and behave more like a single thick layer of the high Young'sModulus material.

SUMMARY

The present disclosure is generally directed to shape-formableapparatuses comprising an envelope that defines a chamber, and a fibrousmaterial positioned in the chamber that can jam or lock together toresist relative movement when the pressure in the chamber is reducedbelow ambient pressure. In some embodiments, apparatuses of the presentdisclosure can further include one or more support sheets positionedadjacent (e.g., in overlapping relationship with) the fibrous materialin the chamber. For example, the apparatus can include two or moresupports sheets with fibrous material positioned between adjacentsupport sheets. In some embodiments employing support sheets, one ormore of the support sheets can include, or be partially formed of, alocking sheet that is configured to “lock” with the fibrous materialand/or with one or more additional sheets (if employed) when thepressure in the chamber is reduced below ambient pressure.

Locking sheets are one example of support sheets that can be employed inapparatuses of the present disclosure. Locking sheets of the presentdisclosure are each patterned into solid and open regions in such a waythat the solid regions can move relative to one another in a majorsurface of the locking sheet, allowing the locking sheets to extendwithin the major surface, and thereby increase the conformability (i.e.,in two or more axes) of the locking sheet. The solid regions can bediscrete and separated from adjacent solid regions, and/or the solidregions can be connected to adjacent solid regions (i.e., continuous),for example, through a path or bridge (e.g., a long and/or tortuouspath) that allows for relative motion between the solid regions within amajor surface of the sheet. When the chamber is under vacuum, thelocking sheets can jam together, e.g., across or through the fibrousmaterial, and/or with the fibrous material to increase the rigidity orstiffness (e.g., one or more of bending stiffness (e.g., effectivebending modulus), tensile stiffness (e.g., effective tensile modulus),and indentation stiffness (e.g., effective indentation modulus)) of theapparatus.

Some aspects of the present disclosure provide a shape-formableapparatus comprising a first state in which the apparatus is formable,such that the apparatus can be formed into a desired shape; and a secondstate in which the apparatus has the desired shape and is substantiallyless formable than in the first state. The apparatus can further includean envelope defining a chamber, the envelope formed of a gas-impermeablematerial; and a port positioned to fluidly couple the chamber withambience. The apparatus can further include a fibrous materialpositioned in the chamber, wherein the fibrous material is substantiallyless formable when the apparatus is in the second state than when theapparatus is in the first state.

Other features and aspects of the present disclosure will becomeapparent by consideration of the detailed description and accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a cutaway perspective view of a shape-formable apparatusaccording to one embodiment of the present disclosure, employing fibrousmaterial.

FIG. 1B is a cutaway perspective view of a shape-formable apparatusaccording to another embodiment of the present disclosure, employingfibrous material and locking sheets comprising continuous solid regions.

FIG. 1C is a cutaway perspective view of a shape-formable apparatusaccording to another embodiment of the present disclosure, employingfibrous material and locking sheets comprising continuous solid regions.

FIG. 2A is a perspective view of a shape-formable apparatus according toanother embodiment of the present disclosure, shown in a first state.

FIG. 2B is a perspective view of the shape-formable apparatus of FIG.2A, shown in a second state.

FIG. 3A is a perspective view of a shape-formable apparatus according toanother embodiment of the present disclosure, shown in a first state.

FIG. 3B is a perspective view of the shape-formable apparatus of FIG.3A, shown in a second state.

FIG. 4 is a top plan view of two locking sheets of FIGS. 1B and 1C,shown in a staggered configuration.

FIG. 5 is a side cross-sectional view of the two locking sheets of FIG.4, with the lower locking sheet shown as including a high frictionsurface.

FIGS. 6A-6C are schematic cross-sectional views of a shape-formableapparatus according to another embodiment of the present disclosure,employing fibrous material and locking sheets comprising continuoussolid regions and high friction surfaces, illustrating a methodaccording to one embodiment of the present disclosure of using theshape-formable apparatus.

FIG. 7 is a cutaway perspective view of a shape-formable apparatusaccording to another embodiment of the present disclosure, employingfibrous material and locking sheets comprising discrete solid regions.

FIGS. 8A-8C are schematic cross-sectional views of a shape-formableapparatus according to another embodiment of the present disclosure,employing fibrous material and locking sheets comprising discrete solidregions and high friction surfaces, illustrating a method according toone embodiment of the present disclosure of using the shape-formableapparatus.

FIG. 9A is a partial perspective view of a shape-formable apparatusaccording to another embodiment of the present disclosure, employinglocking sheets comprising overlapping discrete solid regions.

FIG. 9B is a schematic partial cross-sectional view of theshape-formable apparatus of FIG. 9A.

FIG. 10A is a perspective view of a discrete solid region of a lockingsheet according to one embodiment of the present disclosure.

FIG. 10B is a partial perspective view of a shape-formable apparatusaccording to another embodiment of the present disclosure, the apparatusemploying discrete solid regions of FIG. 10A that overlap along twoaxes.

FIG. 10C is a partial cross-sectional perspective view of theshape-formable apparatus of FIG. 10B, taken along line 10C-10C.

FIG. 10D is a partial cross-sectional perspective view of theshape-formable apparatus of FIG. 10B, taken along line 10D-10D.

FIGS. 11-25 are each a top plan view of a locking sheet comprisingcontinuous solid regions according to another embodiment of the presentdisclosure.

DETAILED DESCRIPTION

The present disclosure generally relates to a shape-formable apparatuscomprising an envelope that defines an internal chamber, and fibrousmaterial positioned in the chamber. As mentioned above, shape-formableapparatuses of the present disclosure can further include one or moresupport sheets positioned in the chamber, and in some embodiments, oneor more of the support sheets can include, or be partially formed of, alocking sheet.

Each locking sheet can be patterned into solid regions and open regions(i.e., gaps or spaces between solid regions), such that at least some ofthe solid regions can move relative to one another within a majorsurface of the sheet. The apparatus has a first state in which theapparatus is formable and is able to be changed into a desiredthree-dimensional shape. The apparatus is further configured to bechanged from the first state into a second state in which thethree-dimensional shape of the apparatus is substantially fixed or rigid(or at least substantially less formable or more rigid than in the firststate), such that the shape can be maintained for a desired purpose. Theapparatus can be changed from the first state to the second state byevacuating the chamber to reduce the pressure in the chamber to belowambient pressure and to remove gas (e.g., substantially all of the gas)from the chamber. The apparatus can be changed from the second state tothe first state by releasing the reduced pressure in the chamber andallowing it to return to ambient pressure. The apparatus can include anopening or a port that provides fluid communication between the chamberand ambience, such that a vacuum source can be coupled to the port via aconnector (e.g., tubing).

The shape-formable apparatuses of the present disclosure can be used fora variety of applications that can benefit from a material or articlethat can be changed from a formable state, in which it can be formedinto a desired shape, to a rigid or non-formable state, in which thedesired shape can be essentially locked for as long as desired. Examplesof such applications, include, but are not limited to, surgical accessretraction, tissue or organ retraction, patient positioning (e.g., tomaintain a patient in a desired position during treatment, therapy,surgery, etc.), packaging (e.g., to hold, separate and/or protectobjects during shipping), home and office storage, organization, and/ordisplay (e.g., modular shelving, drawer separators, etc.),immobilization (e.g., casts to immobilize limbs or joints), othersuitable applications, or combinations thereof.

Methods of using shape-formable apparatuses, e.g., for tissuemanipulation, are described in U.S. Application Nos. 62/094,279 and62/094,336, both filed Dec. 19, 2014, which are each incorporated hereinby reference in their entirety.

Unlike some existing shape-formable devices, some embodiments of theshape-formable apparatuses of the present disclosure take upsubstantially less three-dimensional space, or volume, due to theirsubstantially sheet-like or plate-like configuration. Some existingshape-formable devices are filled with beads or other particulate or“bulk” matter or media. The sheet-like apparatuses of the presentdisclosure can overcome several disadvantages present with existing“bulk” or non-sheet-like devices, including, but not limited to: (i)bulk apparatuses require significant three-dimensional size or space toconform to desired shapes (e.g., to cover or form around an object),with a nominal spherical form factor and relatively largecross-sectional areas; (ii) bulk apparatuses can only apply low forcesto an object; (iii) bulk apparatuses are strongest in compressiveforces; and (iv) bulk apparatuses do not easily conform to a desiredobject or take a desired three-dimensional shape without exertingsignificant force on the object.

Definitions

The term “a”, “an”, and “the” are used interchangeably with “at leastone” to mean one or more of the elements being described.

The term “and/or” means either or both. For example “A and/or B” meansonly A, only B, or both A and B.

The terms “including,” “comprising,” or “having,” and variationsthereof, are meant to encompass the items listed thereafter andequivalents thereof as well as additional items.

Unless specified or limited otherwise, the term “coupled” and variationsthereof are used broadly and encompass both direct and indirectcouplings.

The terms “front,” “rear,” “top,” “bottom,” and the like are only usedto describe elements as they relate to one another, but are in no waymeant to recite specific orientations of the apparatus, to indicate orimply necessary or required orientations of the apparatus, or to specifyhow the invention described herein will be used, mounted, displayed, orpositioned in use.

A “low friction” surface can generally be used to refer to a surfacehaving a low kinetic coefficient of friction. In some embodiments, a lowfriction surface can include a kinetic coefficient of friction of nogreater than about 1, in some embodiments, no greater than about 0.5,and in some embodiments, no greater than about 0.25, when measured on aflat film, sliding against another piece of the same material inaccordance with ASTM D1894-08 Static and Kinetic Coefficients ofFriction of Plastic Film and Sheeting.

A “high friction” surface can generally be used to refer to a surfacehaving a high kinetic coefficient of friction, e.g., when describing alocking sheet alone or relative movement between locking sheets when theapparatus is in the first state. This friction can be achieved throughproperties of the surface material, or through physical structuring ofthe surface (e.g. 3M™ Gripping Material, available from 3M Company, St.Paul, Minn.; www.3 m.com/gripping). In some embodiments, a high frictionsurface can include a kinetic coefficient of friction of at least about1, in some embodiments, at least about 3, and in some embodiments, atleast about 10, when measured on a flat film, sliding against anotherpiece of the same material in accordance with ASTM D1894-08 Static andKinetic Coefficients of Friction of Plastic Film and Sheeting.

The phrases “sheet,” “sheet-like,” “sheet-like configuration,” “plate,”“plate-like,” “plate-like configuration,” or variations thereof, areused to describe an article having a thickness that is small relative toits length and width. The length and width of such articles can define a“major surface” of the article, but this major surface, as well as thearticle, need not be flat or planar. For example, the above phrases canbe used to describe an article having a first ratio (R₁) of thickness(e.g., in a Z direction that is orthogonal to a major surface of thearticle at any point along the major surface) to a first surfacedimension of the major surface (e.g., width or length), and a secondratio (R₂) of thickness to a second surface dimension of the majorsurface, where the first ratio (R₁) and the second ratio (R₂) are bothless than 0.1. In some embodiments, the first ratio (R₁) and the secondratio (R₂) can be less than 0.01; in some embodiments, less than 0.001;and in some embodiments, less than 0.0001. Note that the two surfacedimensions need not be the same, and the first ratio (R₁) and the secondratio (R₂) need not be the same, in order for both the first ratio (R₁)and the second ratio (R₂) to fall within the desired range. In addition,none of the first surface dimension, the second surface dimension, thethickness, the first ratio (R₁), and the second ratio (R₂) need to beconstant in order for both the first ratio (R₁) and the second ratio(R₂) to fall within the desired range.

The phrase “major surface” is used to refer to a collective surface ofan article (e.g., an outer surface of the article), even if the articleis formed of smaller objects or portions. The smaller objects andportions can collectively define a major surface of the article. Whilesuch a major surface can be planar in some instances, the major surfaceneed not be flat or planar, and in some cases, can be curved orotherwise complex. The phrase “major surface” is described in greaterdetail below with respect to the locking sheets 110 of FIGS. 1, 4 and 5.

The phrase “substantially parallel” is used to refer to at least twosheets or sheet-like articles having a major surface, where the majorsurface of the sheets or articles are oriented parallel with respect toone another at any point along their respective major surfaces, butallowing for a slight deviation from parallel. For example, if twosheets have major surfaces that lie in an X-Y plane and are spaced adistance apart in a Z direction that is orthogonal, or normal, to theX-Y plane, the two sheets can be considered substantially parallel evenif one or both of the sheets has a major surface that is orientedslightly out of an orthogonal relationship with the Z direction at agiven point, or area, along the major surface. In some embodiments, thetwo sheets can be substantially parallel if one or both of the sheetshas a major surface that extends in the Z direction by an amount (i.e.,has a Z dimension because the major surface is tilted with respect tothe Z direction) that is no greater than 10% of its dimensions in theX-Y plane; in some embodiments, no greater than 5%; in some embodiments,no greater than 2%; and in some embodiments, no greater than 1%. Notethat two sheets can still be substantially parallel even if the sheetsare not flat or planar. For example, two curved sheets can besubstantially parallel if the two sheets are curved to the same degreeand in the same way so that the orientation of the major surfaces of thetwo sheets, relative to a normal direction at any point, or area, alongthe major surface, still falls within the above ranges.

The terms “polymer” and “polymeric material” refer to both materialsprepared from one monomer such as a homopolymer or to materials preparedfrom two or more monomers such as a copolymer, terpolymer, or the like.The terms “copolymer” and “copolymeric material” refer to a polymericmaterial prepared from at least two monomers.

The terms “room temperature” and “ambient temperature” are usedinterchangeably to mean a temperature in the range of 20° C. to 25° C.

The term “effective tensile modulus” (ETM), which is described ingreater detail below, refers to the slope of the line in a plot oftensile force per unit width versus strain (extension divided byoriginal length), as tested according to the procedure described belowin the Examples section.

The term “effective bending modulus” (EBM), which is described ingreater detail below, refers to the slope of the line in a plot oftensile force per unit width versus a dimensionless approximation ofdeflection angle when a sample is pulled on to induce bending accordingto the procedure described below in the Examples section.

The term “effective indentation modulus” (EIM) refers to the slope ofthe line in a plot of the applied force versus deflection distance whena sample is tested according to the procedure described below in theExamples section called Effective Indentation Modulus.

FIG. 1A illustrates a shape-formable apparatus 100A according to oneembodiment of the present disclosure. The apparatus 100A is generallysheet-like or plate-like, or has a sheet-like or plate-likeconfiguration, as opposed to a three-dimensionally bulky configuration.

As shown in FIG. 1A, the apparatus 100A can include an envelope (orshell, or pouch) 102A that defines an internal chamber 104A; fibrousmaterial 106A; and a port, or opening, 115A in the envelope 102A that ispositioned to fluidly couple the chamber 104A with ambience, and throughwhich the chamber 104A can be evacuated, e.g., by being coupled to avacuum source 120.

For clarity purposes, the top and bottom sides of the envelope 102A areillustrated in FIG. 1A as being substantially spaced apart (i.e., with asidewall joining them). However, in some embodiments, in reality, theapparatus 100A can appear much flatter, having a sheet-like orplate-like configuration.

The apparatus 100A can be configured to be formed into, and held in, adesired shape. That is, the apparatus 100A can have a first state inwhich the apparatus 100A is formable (as further described below), suchthat the apparatus 100A can be formed into a desired three-dimensionalshape (e.g., exhibiting a non-zero Gaussian curvature, as describedbelow). The apparatus 100A can also have a second state in which theapparatus 100A has the desired shape and is substantially rigid, or atleast substantially more rigid than in the first state, and in which thedesired shape is held or locked (i.e., substantially non-formable).

As a result, the apparatus 100A is formable, deformable, conformable,and/or manipulatable in the first state, and substantially not formable,deformable, conformable, and/or manipulatable in the second state. Termssuch as formable, deformable, conformable, and/or manipulatable can beused when describing the ability of the apparatus 100A to take anydesired shape in the first state, the opposite being true when theapparatus 100A is in the second state.

In order to take on any desired three-dimensional shape and be“formable” according to the present disclosure (in the first state), theapparatus 100A exhibits both flexibility (or bendability) andextensibility. For example, a solid sheet of high tensile modulus (e.g.,Young's modulus) material would not be considered to be “formable,”according to the present disclosure, because while it may be bent, itcannot be extended under similar amounts of force (e.g., underreasonable amounts of force, such as forces that can be applied byhand). Generally, an apparatus can exhibit formability when the scale offorces (whether manual or otherwise) required to achieve bending arecomparable to the forces required for extension. For example, if it isdesirable for about 10-50 lb (45-224 N) of force to cause bending of theapparatus, then it should take about 10-50 lb (45-224 N) of force tocause extension of the apparatus. A typical sample of material (modeledsimplistically as a rectangular beam of thickness t, width w, and lengthL, simply supported at two ends) would bend to a maximum deflection of

$\delta_{bend} = \frac{{FL}^{3}}{4{Ewt}^{3}}$

(where L is the length of the beam, and E is the Young's Modulus). Thatsame sample of material would extend by

$\delta_{ext} = {\frac{FL}{Ewt}.}$

The only way to have δ_(bend)˜δ_(ext) for this solid material is ifL˜2t, which is not a sheet or “sheet-like” according to the presentdisclosure.

For simplicity, the first state can be described as a state in which theapparatus 100A is formable or in which the shape (e.g., thethree-dimensional shape) of the apparatus 100A is changeable orunlocked; and the second state can be described as a state in which theapparatus 100A is “rigid,” or in which the shape (e.g., thethree-dimensional shape) of the apparatus 100A is fixed or locked.

The apparatus 100A can be changed into the second state by using thevacuum source 120 to evacuate the chamber 104A (i.e., to remove gas fromthe chamber 104A). After the apparatus 100A has been formed into itsdesired shape and changed from the first state to the second state, theport 115A (or a connector 122, described below) can be sealed and/ordisconnected from the vacuum source 120, and the apparatus 100A canremain in the second state in the desired shape.

FIG. 1B illustrates a shape-formable apparatus 100B according to oneembodiment of the present disclosure, wherein like represent likeelements. The shape-formable apparatus 100B shares many of the sameelements and features described above with reference to the illustratedembodiment of FIG. 1A. Accordingly, elements and features correspondingto elements and features in the illustrated embodiment of FIG. 1A areprovided with the same reference numerals in the 100B series. Referenceis made to the description above accompanying FIG. 1A for a morecomplete description of the features and elements (and alternatives tosuch features and elements) of the embodiment illustrated in FIG. 1B.

The apparatus 100B is generally sheet-like or plate-like, or has asheet-like or plate-like configuration, as opposed to athree-dimensionally bulky configuration.

As shown in FIG. 1B, the apparatus 100B can include an envelope 102Bthat defines an internal chamber 104B; fibrous material 106B; at leasttwo support sheets 108B (illustrated by way of example only as twolocking sheets 110B) positioned in the chamber 104B in an at leastpartially overlapping and substantially parallel configuration, with thefibrous material 106B positioned (e.g., sandwiched) between adjacentsupport sheets 108B; and a port, or opening, 115B in the envelope 102Bthat is positioned to fluidly couple the chamber 104B with ambience, andthrough which the chamber 104B can be evacuated, e.g., by being coupledto a vacuum source (not shown, but such as the vacuum source 120 of FIG.1A).

For clarity purposes, the top and bottom sides of the envelope 102B areillustrated in FIG. 1B as being substantially spaced apart (i.e., with asidewall joining them). Similarly, the support sheets 108B areillustrated as being substantially spaced apart from one another.However, it should be understood that this illustration is used merelyto better and more clearly show how the support sheets 108B can stackwith respect to one another and the fibrous material 106B and can bepositioned in the chamber 104B. In reality, the apparatus 100B canappear much flatter, having a sheet-like or plate-like configuration.

Similar to the apparatus 100A of FIG. 1A, the apparatus 100B of FIG. 1Bcan have a first state in which the apparatus 100B is formable (asfurther described below), and a second state in which the apparatus 100Bhas the desired shape and is substantially rigid, or at leastsubstantially more rigid than in the first state, and in which thedesired shape is held or locked (i.e., substantially non-formable).

FIG. 1C illustrates a shape-formable apparatus 100C according to oneembodiment of the present disclosure, wherein like represent likeelements. The shape-formable apparatus 100C shares many of the sameelements and features described above with reference to the illustratedembodiments of FIGS. 1A and 1B. Accordingly, elements and featurescorresponding to elements and features in the illustrated embodiments ofFIGS. 1A and 1B are provided with the same reference numerals in the100C series. Reference is made to the description above accompanyingFIGS. 1A and 1B for a more complete description of the features andelements (and alternatives to such features and elements) of theembodiment illustrated in FIG. 1C.

The apparatus 100C is generally sheet-like or plate-like, or has asheet-like or plate-like configuration, as opposed to athree-dimensionally bulky configuration.

As shown in FIG. 1C, the apparatus 100C can include an envelope 102Cthat defines an internal chamber 104C; fibrous material 106C; at leasttwo support sheets 108C (illustrated by way of example only as fourlocking sheets 110C) positioned in the chamber 104C in an at leastpartially overlapping and substantially parallel configuration, with thefibrous material (or a portion of fibrous material) 106C positionedbetween adjacent support sheets 108C; and a port, or opening, 115C inthe envelope 102C that is positioned to fluidly couple the chamber 104Cwith ambience, and through which the chamber 104C can be evacuated,e.g., by being coupled to a vacuum source (not shown, but such as thevacuum source 120 of FIG. 1A).

As shown in FIG. 1C, in some embodiments employing more than two supportsheets 108C, fibrous material 106C can be positioned in the spacesformed between all adjacent support sheets 108C. However, it should beunderstood that this need not be the case, and that even when more thantwo support sheets 108C are employed, the fibrous material (or a portionthereof) need not be located in each and every space created betweenadjacent support sheets 108C. By way of example only, FIG. 1C includesfour support sheets 108C (and particularly, four locking sheets 110C)that define three spaces therebetween, and three fibrous materials 106C(or three portions of one or more fibrous materials 106C) located inthese spaces define between adjacent support sheets 108C.

Similar to the apparatuses 100A and 100B of FIGS. 1A and 1B,respectively, the apparatus 100C of FIG. 1C can have a first state inwhich the apparatus 100C is formable (as further described below), and asecond state in which the apparatus 100C has the desired shape and issubstantially rigid, or at least substantially more rigid than in thefirst state, and in which the desired shape is held or locked (i.e.,substantially non-formable).

As mentioned above, the support sheets 108B and 108C of FIGS. 1B and 1Care shown by way of example as including locking sheets 110B and 110C ofthe present disclosure. However, this need not be the case. As shown inFIG. 1A, some embodiments of the present disclosure do not includesupport sheets. As shown in FIGS. 1B and 1C, some embodiments of thepresent disclosure include one or more support sheets 108B and 108C,which will now be collectively referred to as simply support sheets 108.

In some embodiments, the support sheet 108 can be solid, and in someembodiments, as shown in FIGS. 1B and 1C, the support sheets 108 caninclude (i.e., at least a portion of the support sheet 108 can be formedof or include) a locking sheet 110 that is patterned. In someembodiments, as described in greater detail below, and as illustrated inFIGS. 1B and 1C, the locking sheets 110 can each be patterned to includesolid regions 132 and open regions 134 (i.e., openings that pass throughthe thickness of the sheet 110). In addition, in some embodiments, thesupport sheets 108 can be patterned, e.g., to improve the flexibility(bendability) and/or the extensibility of the sheet, without beingformed into solid regions and open regions. That is, in suchembodiments, the support sheet 108 can be patterned, e.g., to formindentations or crease lines, but the patterns are not formed all theway through the thickness of the sheet so as to form open regions orcutouts. Such patterned but not through-cut support sheets will simplybe referred to as “patterned sheets” or “patterned support sheets.” As aresult, in embodiments employing support sheets 108, the support sheetscan include solid sheets, patterned sheets, and/or locking sheets of thepresent disclosure, which are described in greater detail below. Acombination of solid, patterned and locking support sheets can beemployed in one apparatus of the present disclosure, e.g., in analternating or random arrangement.

Solid and patterned support sheets of the present disclosure can besingle or multi-layer (e.g., laminated) constructions and can be formedof a variety of materials, including, but not limited to, paper; ametal, which can be annealed for enhanced softness and malleability(e.g., steel, aluminum); laminated metal layers or foils (e.g., of thesame or different metals); a polymeric material (e.g., polyurethanes,polyolefins), a composite material (e.g., carbon fiber); elastomers(e.g., silicones, styrene-butadiene-styrene); other suitable materials;and combinations thereof.

Patterned sheets of the present disclosure can be formed by a variety ofprocesses, including, but not limited to, embossing, engraving, any ofthe processes listed below for making locking sheets of the presentdisclosure, other suitable processes, or a combination thereof.

FIGS. 2A-2B illustrate a shape-formable apparatus 200 according toanother embodiment of the present disclosure, the apparatus 200 beingsheet-like. Fibrous material of the present disclosure, not shown (withor without support sheets (e.g., locking sheets) of the presentdisclosure, not shown) is contained within a chamber defined by anenvelope 202. The chamber (not shown) can be evacuated via an opening215 and a connector 222, e.g., by connecting the connector 222 to avacuum source (not shown). FIG. 2A shows the apparatus 200 in a firststate in which the chamber inside, and defined by, the envelope 202 isnot evacuated (i.e., is not reduced significantly below ambientpressure). The apparatus 200 can be formed into a desired shape (i.e.,three-dimensional shape) while in the first state. FIG. 2B shows theapparatus 200 after it has been formed into a desired shape and changedfrom the first state to the second state to “lock” (i.e., reversiblylock) the apparatus 200 in the desired shape. The connector 222 is shownin FIGS. 2A and 2B as being integrally formed with the envelope 202,such that the connector 202 is still coupled to the envelope 202 in thesecond state (FIG. 2B), but this need not be the case.

Similarly, FIGS. 3A-3B illustrate a shape-formable apparatus 300according to another embodiment of the present disclosure, the apparatus300 still being sheet-like, but having a tubular configuration. Fibrousmaterial of the present disclosure, not shown (with or without supportsheets (e.g., locking sheets) of the present disclosure, not shown) iscontained within a chamber defined by an envelope 302 and can beoriented, or arranged or elongated substantially parallel with thetubular surfaces of the envelope 302. The fibrous material and/or thesupport sheets (if employed) can also be tubular. In some embodimentsemploying support sheets, one or more support sheets can be positionedabout the tube (e.g., end to end or with ends overlapping). In someembodiments, a single long support sheet can also be wound around itselfmultiple times to create many layers in a tubular shape.

The envelope 302 can be evacuated via an opening 315 and a connector322, e.g., by connecting the connector 322 to a vacuum source (notshown). FIG. 3A shows the apparatus 300 in a first state in which thechamber inside, and defined by, the envelope 302 is not evacuated (i.e.,is not reduced significantly below ambient pressure). The apparatus 300can be formed into a desired shape (i.e., three-dimensional shape) whilein the first state. FIG. 3B shows the apparatus 300 after it has beenformed into a desired shape and changed from the first state to thesecond state to “lock” the apparatus 300 in the desired shape. Theconnector 322 is shown in FIGS. 3A and 3B as being integrally formedwith the envelope 302, such that the connector 302 is still coupled tothe envelope 302 in the second state (FIG. 3B), but this need not be thecase.

The configurations of the apparatuses 200 and 300 of FIGS. 2A-2B and3A-3B, respectively, are shown by way of example only. Any of theadditional details described herein with respect to other embodiments ofshape-formable apparatuses of the present disclosure can also be appliedto the apparatuses 200 and 300, and vice versa.

While not shown in FIGS. 2A-3B, in some embodiments, apparatuses of thepresent disclosure can have an at least slightly reduced volume when inthe second state, as compared to the first state. That is, in someembodiments, apparatuses of the present disclosure in the second statecan be at least partially collapsed, relative to the first state. Insheet-like apparatuses of the present disclosure, the collapse may occurpredominantly in the direction of the thickness of the apparatus (i.e.,the Z direction), which is already small in the first state, relative tothe surface dimensions (i.e., the dimensions defining a major surface ofthe apparatus).

While FIGS. 1A-1C are shown for illustration purposes as three distinctembodiments of the present disclosure, the overall apparatuses 100A,100B and 100C and their individual components (e.g., the envelopes 102A,102B, 10C, the chambers 104A, 104B, 104C, fibrous material 106A, 106B,106C, support sheets 108B, 108C (e.g., including locking sheets 110B,110C) share features and elements. FIGS. 1A-1C merely illustratedifferent combinations and arrangements of elements (e.g., number andarrangement of support sheets 108B, 108C) contained in the chamber 104A,104B, and 104C. Therefore, the apparatuses 100A, 100B, and 100C, andtheir components, will now be collectively described by referring onlyto the numeric portion of the reference numeral (i.e., 100). However, itshould be understood that the disclosure below regarding the genericapparatus 100, and any elements or components thereof, can equally applyto any of the apparatuses 100A, 100B or 100C, and their respectivecomponents, of FIGS. 1A-1C.

The envelope 102 is generally formed of a gas-impermeable material. Theenvelope 102, or a portion thereof (e.g., at least a portion of an outersurface thereof), can be formed of a variety of materials, depending onthe desired use of the apparatus 100. Examples of suitable envelopematerials include, but are not limited to, composite materials,polymeric materials (e.g., elastomeric, thermoplastic, thermoset,biodegradable, or combinations thereof), or combinations thereof. Insome embodiments, the envelope 102, or a portion thereof (e.g., at leasta portion of an outer surface thereof), can be formed of an impermeable(e.g., liquid and gas-impermeable), non-absorbent, microporous, and/ornonporous material that is resistant to harboring bacteria and othersoil. As a result, the envelope 102, or the respective portion thereof,can be easily cleaned and/or disinfected. In addition, in someembodiments, the envelope 102, or a portion thereof, can include anantimicrobial layer or coating to inhibit microbes from collectingand/or growing on the envelope 102. In some embodiments, the envelope102 can be formed of materials that are compatible with commondisinfectants and cleaners, such as oxidizers (e.g., bleach, hydrogenperoxide, dilute peracetic acid, and the like), quaternary ammoniumdisinfectants (e.g. dimethyldidecylammonium bromide), phenolic compounds(e.g. triclosan), cleaning surfactants (e.g. sodium dodecyl sulfate), aswell as solvents (e.g. glycol ethers such as hexyl Cellosolve orhexylCarbitol).

In some embodiments, the envelope 102 can be formed of an elastomericmaterial that is highly extensible and conformable, such that theoverall extensibility or conformability of the apparatus 100 is notlimited by the envelope 102. Said another way, the extensibility and theconformability of the envelope 102 is at least that of the fibrousmaterial 106, one support sheet 108 (if employed), or at least that of aplurality of support sheets 108 (if employed). More specifically, insome embodiments, the envelope 102 can have a tensile modulus (e.g.,Young's modulus, or an effective tensile modulus as set forth in theExamples), a bending modulus (e.g., an effective bending modulus, as setforth in the Examples), and/or an indentation modulus (e.g., aneffective indentation modulus, as set forth in the Examples) that isless than the fibrous material 106, one support sheet 108 (if employed),or a plurality of support sheets 108 (if employed).

In some embodiments, the envelope 102 can exhibit an Effective TensileModulus (e.g., as tested according to the test method described in theExamples section) of no greater than 5 N/mm; in some embodiments, nogreater than 3 N/mm; in some embodiments, no greater than 1.5 N/mm; insome embodiments, no greater than 1 N/mm; in some embodiments, nogreater than 0.5 N/mm; and in some embodiments, no greater than 0.1N/mm. The envelope used in the Examples below was tested by itselfaccording to the method described in the ‘Test Procedures’ section ofthe Examples, and was found to have an Effective Tensile Modulus of 1.21N/mm.

Examples of elastomeric materials can include silicones,polydimethylsiloxane (PDMS), liquid silicone rubber,poly(styrene-butadiene-styrene), other suitable thermoplasticelastomers, and combinations thereof.

Examples of thermoplastic materials can include one or more ofpolyolefins (e.g., polyethylene (high density polyethylene (HDPE),medium density polyethylene (MDPE), low density polyethylene (LDPE),linear low density polyethylene (LLDPE)), metallocene polyethylene, andthe like, and combinations thereof), polypropylene (e.g., atactic andsyndiotactic polypropylene)), polyamides (e.g. nylon), polyurethane,polyacetal (such as Delrin), polyacrylates, and polyesters (such aspolyethylene terephthalate (PET), polyethylene terephthalate glycol(PETG), and aliphatic polyesters such as polylactic acid),fluoroplastics (such as THV from 3M company, St. Paul, Minn.), andcombinations thereof.

Examples of thermoset materials can include one or more ofpolyurethanes, silicones, epoxies, melamine, phenol-formaldehyde resin,and combinations thereof.

Examples of biodegradable polymers can include one or more of polylacticacid (PLA), polyglycolic acid (PGA), poly(caprolactone), copolymers oflactide and glycolide, poly(ethylene succinate), polyhydroxybutyrate,and combinations thereof.

In embodiments employing a polymeric envelope 102, the envelope 102 canbe formed by a variety of methods, including relatively facilemanufacturing methods, such as extrusion, molding, or combinationsthereof.

In some embodiments, one or more surfaces of the envelope 102 (e.g., anouter surface thereof), or a portion thereof, can include a low frictionsurface, which can be achieved by the material composition and/ortexture of the respective surface or by treating the surface (e.g., witha coating, or by coupling a low-friction layer to a desired portion ofthe envelope 102, etc.).

In some embodiments, the apparatus 100 can be in the first state whenthe internal pressure within the chamber 104 is equal to ambientpressure (e.g., about 101 kPa at sea level), or is within +/−5% ofambient pressure. However, the chamber 104 can be at least partiallyevacuated (e.g., by coupling the port 115 to the vacuum source 120 (seeFIG. 1A) and evacuating the chamber 104, i.e., removing gas from thechamber 104) to change the apparatus 100 to the second state, in whichthe internal pressure within the chamber 104 is reduced below ambientpressure (e.g., greater than 5% below ambient pressure).

The vacuum source 120 is only shown schematically in FIG. 1A, but itshould be understood that a variety of suitable vacuum sources can becoupled to the apparatus 100. For example, the vacuum source 120 caninclude, but is not limited to, one or more of a mechanical pump, amanual pump such as a syringe-plunger combination, other suitable vacuumsources that can reduce the pressure in the chamber 104, or acombination thereof.

The vacuum source 120 is shown by way of example only in FIG. 1A asbeing coupled to the port 115 of the apparatus 100 by a connector 122.The connector 122 is illustrated as tubing by way of example. In someembodiments, one or both of the connector 122 and the vacuum source 120can be considered to form a portion of the apparatus 100 (e.g., theenvelope 102 can be integrally formed with or include the connector122); however, in some embodiments, the apparatus 100 can be consideredto be coupled to one or both of the connector 122 and the vacuum source120.

In some embodiments, the fibrous material 106 can be in the form of asheet or can be sheet-like, which can enable the apparatus 100 to remainsheet-like as well. In some embodiments, the fibrous material 106 can beformed of woven or non-woven materials, such as nonwovens availableunder the trade designation 3M™ SCOTCHBRITE™ from 3M Company, St. Paul,Minn. In some embodiments, the fibrous material 106 can be in the formof a bundle of fibers (e.g., loose fibers), and such fibers can includemany shorter fibers, fewer but longer fibers, other suitable bundledfiber configurations, or a combination thereof.

The phrase “fibrous material” refers to a material comprised of fibers,where the individual fibers, or some groups of fibers, have the abilityto move relative to other fibers or fiber groups. That is, in fibrousmaterials of the present disclosure, the fibers (or portions thereof,e.g., in embodiments in which the fibrous material is formed of onecontinuous fiber) are movable relative to one another within the fibrousmaterial (i.e., without damaging the fibers or otherwise changing thenature of the material). Such relative movement of fibers (or portionsthereof) can be due to physical space between the fibers, such as in a3M™ SCOTCHBRITE™ nonwoven (3M Company), or some collection of fibersthat are bonded to each other but with some spacing between the fibers.The physical space allows the fibers to bend and straighten or alignalong an axis even if the fibers are attached to other fibers at one ormore points along their length. In some embodiments, fibers may not bebonded or fixed in any way to other fibers (e.g., as with a mat of steelwool or fiberglass), allowing the fibers the ability to move relative toother fibers. In both cases, the fibers are only restricted frommovement by friction between the fibers, which is generally low atambient pressure, but can be greatly increased by reducing the pressurein the chamber 104 below ambient pressure, causing the fibers to “lock”together. Fibrous materials of the present disclosure do not includematerials such as paper or wood that are made of fibers that cannot moverelative to each other without damaging the fibers or changing thenature of the material.

The fibrous material 106 can be formed of a variety of processesgenerally known to those of skill in the art of fiber making, including,but not limited to, melt-blown processes, spinning processes, extrusionprocesses, any of the fiber processes described below, other suitableprocesses, or a combination thereof.

The fibrous material 106 can be formed of a variety of materials thatare suitable for being processed into fibers, including, but not limitedto, metals (e.g., steel (e.g., steel wool) aluminum, other suitablemetals, or combinations thereof); polymers (e.g., polypropylene (PP),polyethylene terephthalate (PET), polylactic acid (PLA), polyglycolicacid (PGA), other suitable polymeric materials, or combinationsthereof); textiles; ceramics (e.g., ceramic fibers, available under thetrade designation 3M™ NEXTEL™ Ceramic Textiles, from 3M Company, St.Paul, Minn.); composite materials (e.g., fiberglass); other suitablematerials; or combinations thereof.

In some embodiments, as shown in FIG. 1C, multiple fibrous materials 106(or multiple portions or sections of fibrous material 106) can beemployed in the apparatus 100. In such embodiments, the fibrousmaterials 106 need not all be the same type (e.g., nonwoven vs. bundleof fibers, etc.), and need not all be made of the same material. Rather,in some embodiments, the apparatus 100 can include fibrous materials 106of more than one type and/or material makeup. Even in embodiments inwhich the fibrous material 106 is only employed in one volume of space(e.g., as shown in FIGS. 1A and 1B), the fibrous material 106 can stillinclude a combination of various types of fibrous material 106 and/orlayers of fibrous material 106, which need not all be the same.

In general, the fibrous material 106 is formable when the apparatus 100is in the first state, e.g., as a result of the fibers making up thefibrous material 106 being movable past one another and/or relative toany support sheets 108 (if employed). However, when the pressure in thechamber 104 is reduced below ambient pressure and air is removed (oreliminated) from the fibrous material 106, the fibers of the fibrousmaterial 106 can jam against each other, behaving more like a block ofthe material making up the fibers. As a result, if the fibers have ahigh stiffness (e.g., a high effective tensile modulus), then thereduced pressure fibrous material 106, or jammed block of fibrousmaterial 106, will be very stiff, and the apparatus 100 will be verystiff in its second state. The material makeup of the fibers,arrangement of the fibers, and the type of fibrous material 106 can allbe varied to achieve an apparatus having the desired formability in thefirst state and the desired rigidity or stiffness in the second state.

The fibers can be randomly arranged within the chamber 104 of theapparatus 10, or they may be arranged in multiple layers of nominallyparallel fibers (possibly with the fibers of one layer nominallyperpendicular to the next), or they may be woven out of ribbon or looserrove bands of fiber. One or more layers of complex, textile-likepatterns of weaving could also be used to arrange the fibers. If acontinuous length of fiber extends across the apparatus 100 in any oneaxis, then the extensibility and some conformability of the apparatus100 may be lost along that axis. However, a higher bending stiffness(e.g., effective bending modulus) of the apparatus 100 may be achievedwhen vacuum is applied. If the lengths of fiber are overlapping lengthsof fiber that extend across the apparatus 100, then greaterextensibility (and thereby conformability) can be enabled.

In some embodiments, fibers (i.e., forming the fibrous material 106) canbe defined by an aspect ratio, which can be defined as the ratio offiber length to a representative transverse dimension depending on thecross-sectional shape of the fiber (e.g., diameter)). In someembodiments, the fibers forming the fibrous material 106 can have anaspect ratio of at least 10; in some embodiments, at least 20; in someembodiments, at least 25; in some embodiments, at least 30; in someembodiments, at least 50; in some embodiments, at least 75; in someembodiments, at least 100; in some embodiments, at least 250; and insome embodiments, at least 300. In some embodiments, the fibers formingthe fibrous material 106 can have aspect ratio of no greater than 1000;in some embodiments, no greater than 750; and in some embodiments, nogreater than 500.

In some embodiments, fibers can be classified into two classes: (i)short fibers, also known as discontinuous fibers, having an aspect ratioin the range of about 20 to about 60; and (ii) long fibers, also knownas continuous fibers, having an aspect ratio ranging from about 200 toabout 500. In some embodiments, the fibrous material 106 can be formedof short fibers, long fibers, other lengths of fibers, or combinationsthereof.

In some embodiments, satisfactory fibers for use in the fibrous material106 can have (i) a length of between about 20 and about 110 mm inlength, and in some embodiments, between about 40 and about 65 mm, and(ii) a fineness or linear density ranging from about 1.5 to about 500denier, and in some embodiments, from about 15 to about 110 denier. Insome embodiments, fibers of mixed denier can be used in the manufactureof the fibrous material 106 in order to obtain a desired surface textureor finish. The use of larger fibers is also contemplated, and thoseskilled in the art will understand that the invention is not limited bythe nature of the fibers employed or by their respective lengths, lineardensities and the like.

The cross-sectional shape of fibers can also be controlled and adjustedby the use of specific spinneretes, as described in “Applications ofnon-circular cross-section chemical fibers” by Xiaosong Liu, et. Al. inChemical Fibers International 12/2011; 61(4):210-212. The fibers formingthe fibrous material 106 can have a variety of cross-sectional shapes,including, but not limited to, round, square, triangular, oval, hollow(e.g., ring-shaped), star, polygon, cross, “X”, “T”, more complex and/orirregular cross-sectional shapes (e.g., tri-lobal, deep-grooved), othersuitable cross-sectional shapes; and combinations thereof. In addition,the cross-sectional shape and/or dimension of the fibers need not beconstant along its length.

The fibrous material 106 can be formed of a variety of suitable fibers,including natural fibers, synthetic fibers, and combinations thereof.Suitable synthetic fibers can include those made of polyester (e.g.,polyethylene terephthalate), nylon (e.g., hexamethylene adipamide,polycaprolactam), polypropylene, acrylic (formed from a polymer ofacrylonitrile), rayon, cellulose acetate, polyvinylidene chloride-vinylchloride copolymers, vinyl chloride-acrylonitrile copolymers, othersuitable synthetic fibers, and combinations thereof. Suitable naturalfibers can include those of cotton, wool, jute, hemp, other suitablenatural fibers, and combinations thereof.

The fiber used to form the fibrous material 106 can be virgin fibers orwaste fibers reclaimed from garment cuttings, carpet manufacturing,fiber manufacturing, or textile processing, for example. The fibermaterial can be a homogenous fiber or a composite fiber. Compositefibers can include multicomponent fibers, such as bicomponent fibers(e.g., co-spun sheath-core fibers, side-by-side fibers, etc.). It isalso within the scope of the present disclosure to provide a fibrousmaterial 106 comprising different fibers in different portions of theweb (e.g., a first web portion, a second web portion and a middle webportion).

In some embodiments, the fibrous material 106 can be made of, but is notlimited to, an air-laid, carded, stitch-bonded, spunbonded, wet laid, ormelt blown construction. In some embodiments, the fibrous material 106can include an open, lofty, three-dimensional air-laid nonwovensubstrate, as described in U.S. Pat. No. 2,958,593 to Hoover et al., thedisclosure of which is herein incorporated by reference. Such a nonwovenis formed by randomly disposed staple fibers. one example of such anonwoven is available under the trade designation “SCOTCH-BRITE” from 3MCompany, St. Paul, Minn.

Other approaches to the manufacture of fibrous materials of the presentdisclosure include the use of continuous filaments. Exemplary nonwovenarticles made of continuous filaments are those described in U.S. Pat.Nos. 4,991,362 and 5,025,596 to Heyer et al, the disclosures of whichare incorporated herein by reference. These patents describe low-densityabrasive articles formed with continuous, unidirectional crimpedfilament tow with the filaments bonded together at opposing ends of thepad.

In some embodiments, the fibers forming the fibrous material 106 can betensilized and/or crimped (e.g., to add bulk to the fibrous material106), but may also be continuous filaments formed by an extrusionprocess such as that described in U.S. Pat. No. 4,227,350 to Fitzer,which is incorporated herein by reference, as well as the continuousfibers described by the aforementioned '362 and '596 patents to Heyer etal.

In some embodiments, the fibrous material 106 can be formed on a “RandoWebber” machine (commercially available from Rando Machine Company, NewYork) or may be formed by other conventional fiber-making processes. Forexample, in embodiments employing a spunbonded-type fibrous material,the filaments may be of substantially larger diameter, for example, upto 2 millimeters or more in diameter. In addition, it is possible toadjust the process to produce regular helically coiled filaments.Irregular filament undulation is characterized by random looping,kinking or bending of the filaments through the web in a pattern definedgenerally by the pattern of openings of the spinneret. Additionalprocessing is also possible to otherwise crimp, kink or alter the shapeof the fibers. Such kinks or other structures of the fibers canfacilitate intertwined and “locking” of the fibrous material 106 whenthe chamber 104 is evacuated.

In some embodiments, the fibrous material 106 can have a weight per unitarea of at least 20 g/m²; in some embodiments, between 20 and 1000 g/m²,and in some embodiments, between 300 and 600 g/m². Such fiber weightscan provide a web, before needling or impregnation, having a thicknessfrom about 1 to about 200 mm, in some embodiments, from about 6 to about75 mm, and in some embodiments, from about 10 to about 50 mm.

In some embodiments, the fibrous material 106 be reinforced, forexample, by the application of a prebond resin to bond the fibers attheir mutual contact points to form a three-dimensionally integratedstructure, such as that described in Hoover et al. The prebond resin maybe made of a thermosetting water-based phenolic resin. Polyurethaneresins may also be employed. Other useful prebond resins may includethose comprising polyureas, styrene-butadiene rubbers, nitrile rubbers,and polyisoprene. Additional crosslinker, fillers, and catalysts mayalso be added to the prebond resin. Those skilled in the art willappreciate that the selection and amount of resin actually applied candepend on any of a variety of factors including, for example, the fiberweight in the fibrous material 106, the fiber density, the fiber type,and the contemplated end use for the apparatus 100.

Application of the prebond resin, if employed, can be accomplished byany suitable means including roll coating, spray coating, dry powdercoating, suspended powder coating, powder dropping, liquid dip coating,fluidized bed powder coating, electrostatic powder coating, critical gasdilution liquid resin coating, or other commonly used coating processesavailable to those skilled in the art.

Other known means of forming a three-dimensionally integrated structureare within the scope of the present invention. For example, as analternative to a prebond resin applied to the fibers to form the fibrousmaterial 106, the fibers may be melt-bonded together at one or morepoints where they contact one another to form a three-dimensionallyintegrated structure, as described in U.S. Pat. No. 5,685,935 to Heyeret al.

The support sheets 108 are illustrated in FIGS. 1B and 1C as forming astack of support sheets 108 interspersed with the fibrous material 106.For simplicity and by way of example only, the stack in FIG. 1B is shownas including two support sheets 108, and the stack in FIG. 1C is shownas including four support sheets 108. However, it should be understoodthat as few as zero support sheets and as many as structurally possiblecan be employed in apparatuses of the present disclosure. While thesupport sheets 108 of FIGS. 1B and 1C are shown as discrete sheets in astack, it should be understood that “a plurality” (or “more than one” or“at least two”) of support sheets generally means at least twooverlapping sections or portions of support sheets, and the overlappingsections or portions need not actually be discrete sheets, but rather,could be sections or portions of one long sheet that are layered overone another, e.g., by zig-zagging the long sheet, by coiling the sheet,or by otherwise arranging the long sheet such that it includes at leasttwo overlapping portions or sections.

The number of support sheets 108 can be selected to be a number thatprovides sufficient formability of the apparatus 100 in the first state,while also providing sufficient rigidity in the second state for a givenapplication. In some embodiments, the number of support sheets 108employed can depend on the material makeup and the thickness of eachsupport sheets 108.

As mentioned above, in some embodiments, the support sheets 108 caninclude, or be at least partially formed of, one or more locking sheets110. The locking sheets 110 of the present disclosure can be formed of avariety of materials, depending on the desired application or use of theapparatus 100, and can include single or multi-layer constructions.Examples of suitable locking sheet materials include, but are notlimited to, paper; a metal, which can be annealed for enhanced softnessand malleability (e.g., steel, aluminum); a polymeric material (e.g.,ABS, or Delrin), a composite material (e.g., carbon fiber); othersimilar suitable materials, and combinations thereof.

In some embodiments, the support sheets 108 (e.g., locking sheets 110)can all be formed of the same material; however, the support sheets 108employed in one apparatus 100 need not all be formed of the samematerials. In some embodiments, some of the support sheets 108 areformed of the same materials, while other support sheets 108 are formedof one or more different materials. In addition, as mentioned above, thesupport sheets 108 in one apparatus 100 can include a variety of solid,patterned and locking sheets 110. In some embodiments, the supportsheets 108 can be arranged (e.g., stacked) in the chamber 104 accordingto material makeup and/or type (i.e., solid, patterned, and/or locking),such as in an alternating configuration. For example, in someembodiments, a support sheet 108 formed of a first material can bepositioned adjacent a support sheet 108 of a second material, which canbe positioned adjacent a support sheet 108 of the first material, and soon. However, in some embodiments, support sheets 108 of differentmaterials can be arranged in other configurations, or even randomly, inthe chamber 104.

In some embodiments, the support sheets 108 can all have the samethickness (i.e., in a Z direction that is orthogonal to the majorsurface of the support sheet 108); however, in some embodiments, thesupport sheets 108 employed in one apparatus 100 need not all have thesame thicknesses. In some embodiments, some of the support sheets 108can have the same thickness, while other support sheets 108 have one ormore different thicknesses. In some embodiments, the support sheets 108can be arranged (e.g., stacked) in the chamber 104 according tothickness, for example, in order of increasing thickness, decreasingthickness, alternating thickness, another suitable configuration, or acombination thereof. However, in some embodiments, the support sheets108 having different thicknesses can be arranged randomly in the chamber104.

In addition, in some embodiments, one or more support sheets 108 canhave a varying thickness, such that the thickness is not constantthroughout the support sheet 108.

In some embodiments, the patterned and/or locking support sheets 108 ofthe present disclosure can be formed by a variety of methods, includingbut not limited to, extrusion, molding, laser cutting, water jetting,machining, stereolithography or other 3D printing, laser ablation,photolithography, chemical etching, rotary die cutting, stamping,punching, other suitable negative or positive processing techniques, orcombinations thereof.

When the apparatus 100 is in the first state, the support sheets 108 canbe formable, and can slide relative to one another, i.e., such that themajor surfaces of adjacent support sheets 108 slide past one another(e.g., in X and Y directions), and can also move relative to one anotherin a Z direction that is orthogonal to any point along the majorsurfaces of the support sheets 108. However, when the apparatus 100 isin the second state (i.e., when the chamber 104 is evacuated), thesupport sheets 108 can be substantially immovable or “locked” relativeto one another, in the surface (e.g., X and Y) and Z directions, suchthat the apparatus 100 is “substantially/essentially immovable” or“substantially/essentially locked.” This can be particularly true whenthe support sheets 108 include locking sheets 110.

A “substantially/essentially immovable” or “substantially/essentiallylocked” apparatus 100 can also be referred to as “substantially rigid,”“substantially more rigid than in the first state,” or “substantiallyless formable than in the first state,” and, in some embodiments, can becharacterized by comparing a material property (e.g., a measure ofstiffness, such as tensile modulus) of the apparatus 100 when theapparatus 100 is in the second (locked) state with the same materialproperty of the apparatus 100 when the apparatus 100 is in the first(unlocked) state, as described in greater detail below.

While non-locking (e.g., solid or patterned) support sheets 108 can beemployed in the apparatuses of the present disclosure, as describedabove, support sheets 108 in the form of locking sheets 110 are shown inFIGS. 1B and 1C by way of example. The locking sheets 110 of FIGS. 1Band 1C will now be described in greater detail. Additional features anddetails regarding locking sheets of the present disclosure are describedin U.S. Application No. 62/094,240, filed Dec. 19, 2014, which isincorporated herein by reference in its entirety.

As further shown in FIGS. 1B and 1C, at least a portion of each lockingsheet 110 can be patterned or segmented into solid regions 132 and openregions 134 (i.e., gaps or free spaces between solid regions 132), suchthat at least some of the solid regions 132 are movable with respect toone another within a major surface S of the locking sheet 110.

In embodiments employing locking sheets 110, portions of the fibrousmaterial 106 (i.e., fibers or portions of fibers thereof) can aid injamming or locking the apparatus 100 in the second state, e.g., by atleast partially penetrating the open regions 134 of the locking sheets110. In addition, or alternatively, the solid regions 132 of the lockingsheets 110 can jam together with the fibrous material 106; and/or anyhigh friction surfaces of the support sheets 108 (whether locking sheets110 or otherwise) can jam with the fibrous material 106.

For simplicity and clarity of illustration, the locking sheets 110 ofFIGS. 1B and 1C are shown as having a solid outline; however, it shouldbe understood that more likely, the edges of the locking sheets 110 willnot be continuously solid and instead will be made up of the solidregions 132 and the open regions 134, and possibly incomplete portionsof solid regions 132. For simplicity and clarity purposes, one lockingsheet 110 will now be described in greater detail; however, it should beunderstood that the additional details described below can be applied toany locking sheet 110 of the apparatus 100.

By way of example only, the top (or bottom) surfaces of the individualsolid regions 132 of the first locking sheet 110 of FIG. 4 collectivelydefine one or more major surfaces of the locking sheet 110. Oneexemplary major surface S is shown in FIGS. 1B, 1C and 4 and is shown asbeing substantially planar for simplicity, but as the locking sheet 110is formed into a desired shape (e.g., by being formed over an object, orconforming to a complex surface), the major surface S can take on anycomplex shape. Such a complex shape can be possible, because the solidregions 132 are movable relative to one another within the major surfaceS. That is, the shape of the major surface S can change (e.g., due tothe relative movement of the solid regions 132 defining the majorsurface S), and can be very complex. However, no matter what shape themajor surface S has, the solid regions 132 can be movable relative toone another within the major surface S. Such movement can includebending relative to one another (e.g., deflecting in and out of themajor surface S, but also redefining the major surface S in doing so),such that the resulting locking sheet 110 is bendable, and also movingtoward and away from one another, such that the resulting locking sheet110 is extensible. This combination of flexibility (bendability) andextensibility creates a formable locking sheet 110.

While it is understood that the solid regions 132 also have a thicknessin a Z direction that is orthogonal to the major surface S, there willbe a major surface (e.g., the major surface S) that is collectivelydefined by the solid regions 132, and the solid regions 132 will bemovable within that major surface. The solid regions 132 may also bemovable relative to one another into and out of that major surface, orrelative to one another in the Z direction. However, a keydistinguishing property of the locking sheets of the present disclosureare that they are patterned into solid regions and open regions in sucha way that the solid regions are at least movable relative to oneanother within a major surface of the locking sheet 110.

The relative movement of solid regions 132 both in and out of a majorsurface of the locking sheet 110 allow the sheet to form into anyspatial surface. For example, the locking sheet 110 could be smoothlyformed around a sphere or even the contours of a human face withoutwrinkling. This is possible because the solid regions 132 can both bendand extend within the major surface relative to each other. The abilityof a locking sheet 110 (or a plurality of locking sheets 110) to morphinto any desired spatial surface topology may be limited by the size andflexibility/extensibility of the solid regions 132, which defines a sortof spatial resolution of the locking sheet 110 that can be adjusted tosuit the application.

Particularly, the solid regions 132 can move within the major surfacerelative to one another from a first position to a second position, andmore particularly, can move relative to one another from a firstposition to a second position that can be maintained without any plasticdeformation of the material forming the locking sheet 110. This is incontrast to a sheet of material in which openings have been cut suchthat material has simply been removed to form the sheet, or a sheet ofmaterial formed of woven pieces or strands of material. In such sheets,the openings may provide space for the solid portions to slightly moveor wiggle relative to one another, but not from a first position to asecond position that can be maintained without plastic deformation. Forexample, if the solid portions of such sheets are moved such that thestress applied extends the material within its elastic limit, thematerial will return to its first position as soon as the stress isremoved; and if the material is moved such that the stress appliedextends the material beyond its elastic limit, plastic deformation willoccur. That is, if a sheet of material included only continuous stripsor strands of material in one or more directions, the sheet's materialproperties in those one or more directions would be equal to thematerial properties of the material making up the continuous strips orstrands. On the contrary, the locking sheets 110 of the presentdisclosure are formed of a material, but include different overallmaterial properties than the properties of the material itself, andparticularly, in any direction in which the material property is tested.

In some embodiments, relative motion of solid regions within a majorsurface can be characterized or quantified by material property ratiosthat compare a given material property for the material making up thesolid regions 132 to an overall material property for the locking sheet110 that results from the patterning or segmenting of the sheet intosolid regions 132 and open regions 134. That is, a solid piece ofmaterial (e.g., steel, paper, etc.) will behave substantiallydifferently from a locking sheet 110 of the present disclosure (i.e.,having solid regions 132 and open regions 134) that is formed of thatsame material.

For example, the locking sheet 110 can be formed of a material having afirst effective tensile modulus (E_(o)), and the solid regions 132 andopen regions 134 can be arranged such that the locking sheet 110 has anoverall effective tensile modulus (E₁; e.g., when tested in any or allsurface directions within a major surface of the locking sheet 110), andthe ratio of E₀/E₁ is at least 2; in some embodiments, at least 3; insome embodiments, at least 4; in some embodiments, at least 5; in someembodiments, at least 10; in some embodiments, at least 20; in someembodiments, at least 50; in some embodiments, at least 100; in someembodiments, at least 1000; and in some embodiments, at least 10,000. Insome embodiments, the ratio of E_(o)/E₁ can be no greater than 100,000;in some embodiments, no greater than 50,000; and in some embodiments, nogreater than 25,000.

In some embodiments, the overall effective tensile modulus E₁ can varyover the major surface of the locking sheet 110, so that the effectivetensile modulus E₁ over a first area or portion of the locking sheet 110may not be the same as it is over a second area or portion, but theratio of E_(o)/E₁ at the first area is at least 2, and the ratio ofE_(o)/E₁ at the second area is at least 2. That is, even if the overallstiffness of the locking sheet 110 varies over the sheet, the ratio ofE_(o)/E₁ at any given location, portion or area of the locking area isstill at least 2.

In some embodiments, the locking sheet 110 can be formed of a materialhaving a first effective tensile modulus (E_(o)), and the solid regions132 and open regions 134 can be arranged such that the apparatus 100 asa whole has an overall effective tensile modulus (E_(a)) while in thefirst or unlocked state, and the ratio of E_(o)/E_(a) is at least 2; insome embodiments, at least 3; in some embodiments, at least 4; in someembodiments, at least 5; in some embodiments, at least 10; in someembodiments, at least 20; in some embodiments, at least 50; in someembodiments, at least 100; in some embodiments, at least 1000; and insome embodiments, at least 10,000. In some embodiments, the ratio ofE_(o)/E_(a) can be no greater than 100,000; in some embodiments, nogreater than 50,000; and in some embodiments, no greater than 25,000.

In some embodiments, the overall effective tensile modulus E_(a) of theapparatus 100 in the first (unlocked) state can vary across theapparatus 100, so that the overall effective tensile modulus E_(a) overa first area or portion of the apparatus 100 may not be the same as itis over a second area or portion, but the ratio of E_(o)/E_(a) at thefirst area is at least 2, and the ratio of E_(o)/E_(a) at the secondarea is at least 2. That is, even if the overall stiffness of theapparatus 100 varies over the sheet, the ratio of E_(o)/E_(a) at anygiven location, portion or area of the locking area is still at least 2.

In some embodiments, the locking sheet 110 can be formed of a materialhaving a strain at yield (ε₀) (i.e., the strain at the elastic limit orat the onset of plastic deformation, as defined or determined bystandard methods for a particular material in question), and the solidregions 132 and the open regions 134 can be arranged such that thelocking sheet 110 formed that material can be operated beyond thatstrain limit and still not encounter plastic deformation. For example,in some embodiments, the material forming the solid regions 132 of thelocking sheet 110 has a strain at yield (ε₀), the solid regions 132 andthe open regions 134 are arranged such that the locking sheet 110 isconfigured to experience a strain (ε₁) without yielding of any materialwhen the apparatus is in the first state, and wherein the strain ratioof ε₁/ε₀ is at least 1; in some embodiments, at least 2; in someembodiments, at least 3; in some embodiments, at least 5; in someembodiments, at least 10; in some embodiments, at least 50; in someembodiments, at least 100; in some embodiments, at least 1000; in someembodiments, at least 10,000; in some embodiments, at least 50,000; andin some embodiments, at least 100,000.

In some embodiments, at least partly due to the conformability of thefibrous material 106 and/or the relative motion of the solid regions 132within a major surface of the locking sheet 110 (if employed), theapparatus 100, the fibrous material 106, and/or the locking sheet 110(if employed) can exhibit three-dimensional conformability when in thefirst state. Conformability can be defined as the ability of theapparatus 100 to be formed over (i.e., substantially conform to) athree-dimensional object (e.g., a sphere or a more complexthree-dimensional object) with little to no wrinkling (e.g., gathering)of the apparatus 100.

For example, in some embodiments, the apparatus 100, the fibrousmaterial 106, and/or the locking sheet 110 can substantially conform toa complex surface having a non-zero Gaussian curvature in the firststate, such that the apparatus 100, the fibrous material 106, and/or thelocking sheet 110 can exhibit simultaneous curvature about twoorthogonal axes, e.g., that requires a change in area in the plane ofdeformation. For example, a solid piece of paper cannot substantiallyconform to a surface having non-zero Gaussian curvature (i.e., the paperwould gather and form wrinkles in doing so). However, a piece of paperthat has been segmented or patterned to include solid regions and openregions in such a way that the solid regions are movable with respect toone another in a major surface of the piece of paper (e.g., a patternedor segmented piece of paper that exhibits a ratio of E_(o)/E₁ of atleast 10 (e.g., in any direction)) can substantially conform to acomplex surface having a non-zero Gaussian curvature.

A complex surface having a non-zero Gaussian curvature is just oneexample of a complex surface to which the apparatus 100, the fibrousmaterial 106, and/or the locking sheet 110 can substantially conform inthe first state. It should be understood that due to the formability(i.e., combination of flexibility (bendability) and extensibility) ofthe apparatus 100, the fibrous material 106, and/or the locking sheet110, the apparatus 100 and/or the locking sheet 110 can substantiallyconform to other complex non-Gaussian surfaces as well.

In some embodiments, a stiffness ratio (as described below, or any ofthe below-described modulus ratios) of the first and second states canbe used to define and distinguish the first “formable” state of theapparatus 100 and the second “rigid” state of the apparatus 100.

In some embodiments, the first and second states of the apparatus 100can be characterized and/or distinguished by a stiffness ratio(S_(L)/S_(UL)). The stiffness ratio (S_(L)/S_(UL)) can be the ratio of asecond (or locked) stiffness, S_(L), (e.g., one or more of tensilemodulus, bending modulus, indentation modulus, or another suitablemodulus) of the apparatus 100 when the apparatus 100 is in the secondstate to a first (or unlocked) stiffness, S_(UL), of the apparatus 100when the apparatus 100 is in the first state.

In some embodiments, the stiffness ratio (S_(L)/S_(UL)) can be at least2, in some embodiments, at least 3, in some embodiments, at least 4, insome embodiments, at least 5, in some embodiments, at least 8, in someembodiments, at least 10, in some embodiments, at least 15, in someembodiments, at least 20, in some embodiments, at least 40, and in someembodiments, at least 50.

As a result, in some embodiments, the apparatus 100 can be described ashaving a first state and a second state, as described above, where thestiffness ratio (S_(L)/S_(UL)) of the stiffness of the apparatus 100 inthe second state to the stiffness of the apparatus 100 in the firststate is at least 2, in some embodiments, at least 3, and so on. Saidanother way, the second state can be characterized as a state in whichthe apparatus 100 has a stiffness that is at least 2 times the stiffnessof the apparatus 100 in the first state, in some embodiments, at least 3times the stiffness of the apparatus 100 in the first state, and so on.Said yet another way, the first state can be characterized as a state inwhich the apparatus 100 has a stiffness that is no greater than ½ thestiffness of the apparatus 100 in the second state; in some embodiments,no greater than ⅓ the stiffness of the apparatus 100 in the secondstate, and so on.

In some embodiments, the first and second states of the apparatus 100can be characterized and/or distinguished by a specific modulus ratio.For example, in some embodiments, the first state can be characterizedby a first (unlocked) effective tensile modulus (E_(UL)), and the secondstate can be characterized by a second (locked) effective tensilemodulus (E_(L)), and the ratio (E_(L)/E_(UL)) of the second modulus tothe first modulus can be at least 2, in some embodiments, at least 3, insome embodiments, at least 4, in some embodiments, at least 5, in someembodiments, at least 8, in some embodiments, at least 10, in someembodiments, at least 15, in some embodiments, at least 20, in someembodiments, at least 40, and in some embodiments, at least 50.

The term “Effective Tensile Modulus” (ETM) refers to the slope of theline in a plot of tensile force per unit width versus strain (extensiondivided by length) as tested according to the procedure described laterin the Examples section called Effective Tensile Modulus. This modulusis similar to Young's Modulus, but adapted to the testing of thinsheet-like materials by replacing the stress axis with force per unitwidth of the sheet material, where the width is measured normal to thedirection of the applied tensile force. The strain is measured in theconventional sense by dividing the increased extension of the sample byits original length (i.e. ΔL/L). This Effective Tensile Modulus isuseful for measuring the apparatus 100 and locking sheets 110 of thepresent disclosure because the cross-sectional area of those objects canbe difficult to measure (particularly, the locking sheets 110 that arepatterned into solid regions 132 and open regions 134).

In some embodiments, the first state can be characterized by a first(unlocked) effective bending modulus (B_(UL)), and the second state canbe characterized by a second (locked) effective bending modulus (B_(L)),and the ratio (B_(L)/B_(UL)) of the second modulus to the first moduluscan be at least 2, in some embodiments, at least 3, in some embodiments,at least 4, in some embodiments, at least 5, in some embodiments, atleast 8, in some embodiments, at least 10, in some embodiments, at least15, in some embodiments, at least 20, in some embodiments, at least 40,and in some embodiments, at least 50.

The term “Effective Bending Modulus” (EBM) refers to the slope of theline in a plot of tensile force per unit width versus a dimensionlessapproximation of deflection angle when a sample is pulled on to inducebending according to the procedure described below in the Examplessection called Effective Bending Modulus. This modulus is adapted to thetesting of thin sheet-like materials by using force per unit width ofthe sheet material, where the width is measured normal to the directionof the applied bending force. The resulting bend angle is approximatedby dividing the distance that the end of the sheet moves under theapplied load by the length of the sheet, from the clamp to the appliedload. Similar to the Effective Tensile Modules, this modulus is usefulfor measuring the apparatus 100 and locking sheets 110 because thecross-sectional area of those objects can be difficult to measure(particularly, the locking sheets 110 that are patterned into solidregions 132 and open regions 134). This EBM is also useful becausepatterned locking sheets 110 can lack the strength to support themselvesacross supports to be measured for bending in a more traditionalprocedure.

In some embodiments, the first state can be characterized by a first(unlocked) effective indentation modulus (I_(UL)), and the second statecan be characterized by a second (locked) effective indentation modulus(I_(L)), and the ratio (I_(L)/I_(UL)) of the second modulus to the firstmodulus can be at least 2, in some embodiments, at least 3, in someembodiments, at least 4, in some embodiments, at least 5, in someembodiments, at least 8, in some embodiments, at least 10, in someembodiments, at least 15, in some embodiments, at least 20, in someembodiments, at least 40, and in some embodiments, at least 50.

The term “Effective Indentation Modulus” (EIM) refers to the slope ofthe line in a plot of the applied force versus deflection distance whena sample is tested according to the procedure described below in theExamples section called Effective Indentation Modulus. The diameter ofthe ring used during the procedure should be specified since it willaffect the readings. If the same diameter ring is used, then this is aneffective procedure for comparing various sheets of material. This testmeasures to some extent the ability of a sheet to bend and also toextend. It therefore has a correlation with the conformability of thesheet. However, the test does not differentiate between materials thatwrinkle instead of deforming their shape in a substantially continuousmanner.

In some embodiments, the first state of the apparatus 100 can becharacterized by the apparatus 100 having an effective tensile modulus(as defined herein) of less than 20 N/mm in some embodiments, less than10 N/mm in some embodiments, less than 5 N/mm in some embodiments, andin some embodiments less than 1 N/mm.

In some embodiments, the solid regions 132 in the locking sheet 110 canbe continuous, i.e., connected to one or more adjacent solid regions132; and in some embodiments, the solid regions 132 can be discrete orseparated from adjacent solid regions 132 in a major surface of thelocking sheet 110. In some embodiments employing locking sheets 110, theapparatus 100 can include all continuous locking sheets 110 (i.e.,employing continuous solid regions 132) or all discontinuous lockingsheets 110 (i.e., employing discrete solid regions 132). In someembodiments employing locking sheets 110, the apparatus 100 can includea combination of continuous and discrete solid region locking sheets110. That is, in some embodiments, at least one locking sheet 110 in theapparatus 100 can include continuous solid regions 132, and at least onelocking sheet 110 in the apparatus 100 can include discrete solidregions 132.

In some embodiments employing a plurality of locking sheets 110, theplurality of locking sheets 110 in the apparatus 100 can all have thesame pattern (as shown in FIGS. 1B and 1C), can all have a differentpattern, or a combination thereof. Any arrangement of patterns ispossible. For example, in some embodiments, the locking sheets 110 ofdifferent patterns can be arranged in an alternating fashion (e.g., A,B, A, B, etc.), can be arranged in a block pattern (e.g., A, A, B, B,etc.), or a combination thereof (e.g., A, A, B, B, A, A, etc.). Still,in some embodiments, locking sheets 110 of different patterns can bearranged (i.e., stacked) randomly.

In some embodiments employing at least two locking sheets 110 of thesame pattern, two identically-patterned locking sheets 110 can bearranged to substantially align with one another, such that the solidregions 132 in one locking sheet 110 substantially overlap and alignwith the solid regions 132 in an adjacent (i.e., above or below) lockingsheet 110, as shown in FIGS. 1B and 1C.

However, in some embodiments, as shown in FIG. 4, twoidentically-patterned locking sheets 110 can be staggered with respectto one another, such that solid regions 132 in a first locking sheet 110overlap open regions 134′ in a second locking sheet 110′, and openregions 134 in the first locking sheet 110 overlap solid regions 132′ inthe second locking sheet 110′. In FIG. 4, the top, first locking sheet110 is shown in white, and the bottom, second locking sheet 110′ hassolid regions 132′ shown in light gray and open regions 134′ shown indarker gray. More specifically, in some embodiments employing continuoussolid regions 132, as shown in FIGS. 1 and 4, the solid regions 132 caninclude islands and one or more connections, or bridges, positioned toconnect each island to an adjacent island.

FIG. 4 and FIG. 5 (described below) can be representative of two of aplurality of locking sheets 110 employed in the apparatus 100. As shownin FIGS. 1B and 1C, in some embodiments employing locking sheets 110,the fibrous material 106 can be positioned between adjacent lockingsheets 110; however, the fibrous material 106 is removed from FIGS. 4and 5 for clarity purposes. It should be understood that any of thefeatures and elements of the locking sheets 110 of FIGS. 4 and 5 can beemployed in apparatuses of the present disclosure comprising fibrousmaterial, and that fibrous material can be employed between adjacentlocking sheets 110 but need not be employed in each and every spaceformed between adjacent locking sheets 110.

As shown in FIG. 4, the first locking sheet 110 includes islands 136having an octagonal shape, and each island 136 is connected to one ormore adjacent islands 136 by one or more bridges 138, respectively. Theislands 136 are arranged in a square-packed arrangement, such that thepattern of the locking sheet 110 includes a repeat unit, or unit cell,comprising one central octagonal island 136 that is connected to fouradjacent islands 136 by four bridges 138, respectively, that areequally-spaced about the island 136, such that every other octagonaledge of each island 136 is connected to a bridge 138. By way of example,each bridge 138 includes a 90-degree bend, and each bridge 138 comingfrom the same island 136 bends in the same direction (i.e., clockwise orcounter-clockwise), such that the open regions 134 include asubstantially square space between four adjacent islands 136 thatincludes two bridges 138, and such that the pattern of the first lockingsheet 110 includes 4-fold rotational symmetry about the center of eachisland 136.

Furthermore, due to the dense packing of the islands 136, the patternincludes staggered horizontal rows of islands 136, staggered verticalrows of islands 136, and diagonal rows of islands 136. Each island 136has bridges 138 bending in the same direction (i.e., clockwise orcounter-clockwise) as that of any island 136 in the same horizontal row,but in the opposite direction as that of any island 136 in an adjacenthorizontal row. Similarly, each island 136 has bridges 138 bending inthe same direction (i.e., clockwise or counter-clockwise) as that of anyisland 136 in the same vertical row, but in the opposite direction asthat of any island 136 in an adjacent vertical row. However, each island136 has bridges 138 bending in the opposite direction as that of anadjacent island 136 in the same diagonal row (in any direction).

The second locking sheet 110′ the same pattern as the first lockingsheet 110, i.e., also includes islands 136′ and bridges, but the bridgesin the second locking sheet 110′ are not visible in FIG. 4, because theislands 136 in the first locking sheet 110 are positioned to overlap thebridges of the second locking sheet 110′. In addition, each island 136in the first locking sheet 110 also partially overlaps four islands 136′in the second locking sheet 110′.

The specific pattern of the locking sheets 110, 110′ of FIG. 4 is shownby way of example only, and particularly, to illustrate how adjacentlocking sheets 110 (e.g., employing the same pattern) in the apparatus100 can be staggered so that solid regions 132 in one locking sheet 110can overlap open regions 134′ in an adjacent locking sheet 110.

Examples of discontinuous locking sheets (i.e., employing discrete solidregions) are illustrated in FIGS. 7-10D and described below. Additionalexamples of continuous locking sheets (i.e., employing continuous solidregions) are illustrated in FIGS. 11-25 and described below.

In addition, or alternatively, in some embodiments, adjacent lockingsheets 110 in the apparatus 100 (e.g., whether having the same ordifferent patterns) can be rotated with respect to one another about az-axis that is substantially orthogonal with respect to, or normal to,each locking sheet 110. That is, in some embodiments, even if thelocking sheets 110 include the same pattern, one or more locking sheets110 can be rotated with respect to one another, such that the patternsdo not directly and identically overlap one another. For example, insome embodiments, a first locking sheet 110 can be rotated about thez-axis at an angle of 90 degrees with respect to a second locking sheet110. In some embodiments, e.g., if more than two locking sheets 110 areemployed, the locking sheets 110 can be arranged such that the patternrotation alternates with each sheet, such that a first and a third sheetmay exactly overlap (i.e., are not rotated with respect to one another),while a second and a fourth sheet exactly overlap one another, but arerotated at an angle with respect to the first and the third sheets. Inother embodiments, each locking sheet 110 can be rotated at an anglewith respect to each adjacent locking sheet 110. For example, a secondlocking sheet 110 can be rotated at an angle of 90 degrees with respectto a first locking sheet 110, a third locking sheet 110 can be rotatedan angle of 90 degrees with respect to the second locking sheet 110, andso on.

In some embodiments, one locking sheet 110 can include more than onepattern of solid regions 132 and open regions 134. That is, in someembodiments, the pattern within a given locking sheet 110 need not beconstant. For example, the pattern near the periphery of a locking sheet110 can be different from the pattern near the center of the lockingsheet 110, or the pattern can change, or even be random, throughout agiven locking sheet 110.

In some embodiments, one or more locking sheets 110 can be fixed (e.g.,pinned or glued) to the envelope 102 and/or one or more other lockingsheets 110 in one or more points or locations. In such embodiments, thelocking sheet(s) 110 can be coupled to the envelope 102 and/or otherlocking sheet(s) 110 by any of the coupling means described below withrespect to coupling discrete solid regions 532 of FIG. 7 to an envelope502.

That is, in some embodiments, at least one locking sheet 110 in theapparatus 100 can include a varying pattern of solid regions 132 andopen regions 134. Such variations in a pattern can themselves follow apattern, can be a block pattern (e.g., one pattern on one half of thelocking sheet 110 and a different pattern on the other half), can berandom, or a combination thereof.

In some embodiments, the locking sheets 110, or a portion thereof (e.g.,a surface 125, 125′ (see FIGS. 4 and 5) oriented to face the fibrousmaterial 106 and/or another locking sheet 110), can include a highfriction surface, which can be achieved by the material compositionand/or texture of the respective surface or by treating the surface(e.g., with a coating, by coupling a high-friction layer to a desiredportion of the locking sheet 110, etc.). Such high friction surfaces canfacilitate jamming together of the locking sheets 110 with one or moreother locking sheets 110 and/or with the fibrous material 106 as theapparatus 100 is changed to the second state. As a result, such highfriction surfaces can enhance the stiffness (e.g., any of theabove-described types of stiffness) of the apparatus 100 in the secondstate. While FIGS. 4 and 5 illustrate locking sheets 110, 110′, itshould be understood that any support sheet of the present disclosurecan include a surface that is oriented to face the fibrous material 106and/or another support sheet, and that such a surface can include a highfriction surface.

In some embodiments, high friction surfaces can be an inherent result ofa manufacturing process. For example, paper can itself have asufficiently high friction surface for two locking sheets 110 made ofpaper to inter-engage under vacuum. In other embodiments, high frictionsurfaces can be formed by one or more of embossing, knurling, anysuitable microreplication process, abrading, sand-blasting, molding,stamping, vapor deposition, other suitable means of forming a highfriction surface, or combinations thereof.

FIG. 5 shows a side cross-sectional view of a portion of the twostaggered, overlapping locking sheets 110, 110′ of FIG. 4. In FIG. 5,the foreground solid regions 132, 132′ that include islands 136, 136′and foreground open regions 134, 134′ are shown, but the bridges 138 andbackground islands 136, 136′ are removed from each locking sheet 110,110′ for clarity. As mentioned above, the fibrous material 106 can bepositioned in at least a portion of the space formed between the lockingsheets 110, 110′.

As shown in FIG. 5, each locking sheet 110, 110′ includes a surface 125,125′ configured to face the other locking sheet 110′, 110. However, thesurface 125′ of the second locking sheet 110′ is shown as including ahigh friction surface, and particularly, a high friction surface 125′that is structured to include engagement features 140′ that extend inthe Z direction toward the first locking sheet 110 (or have a Zdimension in the direction of the first locking sheet 110). By way ofexample only, the engagement features 140′ are shown as beingequally-spaced posts. One example of a suitable structured high frictionsurface that can be employed on locking sheets of the present disclosureis a textured or structured material available under the tradedesignation, “3M™ Gripping Material” from 3M Company, St. Paul, Minn.

The entire surface 125′ need not include the high friction surfacefeatures, but rather, in some embodiments, only a portion of the surface125′ is a high friction surface. In the embodiment shown in FIG. 5, eachisland 136′ of the second locking sheet 110 is shown by way of exampleonly as including posts or pegs. In some embodiments, these posts can bedistributed over the entire area of each island 136′, and in someembodiments, the posts can be distributed over a portion of the area ofsome or all of the islands 136′.

The posts are illustrated by way of example only as being tall, thin,pin-like, cylindrical posts; however, it should be understood that avariety of structure shapes can be employed in structured high frictionsurfaces of the present disclosure, including, but not limited to, postsof other cross-sectional shapes (e.g., square, triangular, polygonal,etc.), square pyramids, triangular pyramids, other suitable shapes, orcombinations thereof.

Although not shown in FIG. 5, in some embodiments, the first lockingsheet 110 can include openings or recesses that are dimensioned toreceive (i.e., inter-engage with) the engagement features 140′ of thesecond locking sheet 110′. Alternatively, or additionally, the surface125 of the first locking sheet 110 can also include engagement featuresthat extend in the Z direction toward the second locking sheet 110′ andthat can inter-engage, or interlock, with the structures 140′ of thesecond locking sheet 110′. In such embodiments, the engagement featureson the first locking sheet 110 need not be the same as those on thesecond locking sheet 110′, as long as the engagement features can stillinter-engage with the structures 140′. Because the first and secondlocking sheets 110, 110′ can each include one or more posts orextensions, one or more recesses or openings, or a combination thereof,the first locking sheet 110 can generally be described as having asurface 125 including a plurality of first engagement features, and thesecond locking sheet 110′ can be described as having a plurality ofsecond engagement features that are configured to engage the pluralityof first engagement features.

It should be understood that the staggered configuration of FIG. 5 isshown by way of example only, and that high friction surfaces (e.g.,including inter-engaging engagement features) can be employed innon-staggered (e.g., aligned) locking sheets as well.

In some embodiments, particularly, in staggered configurations, the openregions 134 in the first locking sheet 110 can be dimensioned tointer-engage with the engagement features 140′ of the second lockingsheet 110′, such that the open regions 134 of the first locking sheet110 can function as the plurality of first engagement features. In otherembodiments, locking sheets 110, 110′ can be patterned such that thesolid regions 132, 132′ in the first and second locking sheets 110, 110′can tilt or rotate even slightly out of the major surface of theirrespective locking sheet 110 as the solid regions 132 move relative toone another in the major surface of the respective locking sheet 110,i.e., when the apparatus 100 is formed into a desired shape. In suchembodiments, the tilted or rotated solid regions 132, 132′ in the firstor second locking sheet 110 or 110′ can inter-engage with the solidregions 132′, 132 and/or the open regions 134′, 134 in the other lockingsheet 110′ or 110, respectively.

While structures on adjacent locking sheets 110 can be described asinter-engaging, it should be understood that such inter-engagingstructures are generally reversibly inter-engaged, so that the apparatus100 can be changed from the first state to the second state, andreturned to the first state again, as desired. This can provide for theformability of the apparatus 100 not being lost after the first time theapparatus 100 is changed to the second state.

FIGS. 6A-10D illustrate various shape-formable apparatuses of thepresent disclosure, wherein like numerals represent like elements. Theshape-formable apparatuses of FIGS. 6A-10D share many of the sameelements, features, and functions as the apparatus 100 described abovewith respect to FIGS. 1A-1C, 4 and 5. Reference is made to thedescription above accompanying FIGS. 1A-5 for a more completedescription of the features and elements (and alternatives to suchfeatures and elements) of the embodiments illustrated in FIGS. 6A-10D.Any of the features described above with respect to FIGS. 1A-1C, 4and/or 5 can be applied to any of the embodiments of FIGS. 6A-10D, andvice versa.

FIGS. 6A-6C illustrate a shape-formable apparatus 400 according toanother embodiment of the present disclosure, employing fibrous material406 and continuous locking sheets 410 comprising continuous solidregions 432, open regions 434, and surfaces 425 configured to face thefibrous material 406 and/or an adjacent locking sheet 410. The apparatus400 is generally sheet-like or plate-like, or has a sheet-like orplate-like configuration, as opposed to a three-dimensionally bulkyconfiguration. FIGS. 6A-6C also illustrate a method according to oneembodiment of the present disclosure of using the shape-formableapparatus 400.

The apparatus 400 includes an envelope 402 that defines a chamber 404, afibrous material 406, locking sheets 410, a port 415, a connector 422,and a vacuum source 420 that are each shown schematically merely forpurposes of illustration. While the solid regions 432 and the openregions 434 of the locking sheets 410 are shown schematically forillustration purposes, it should be understood that the locking sheets410 are patterned just like any other locking sheet of the presentdisclosure and are intended to represent continuous locking sheets ofthe present disclosure (i.e., employing continuous solid regions 432,such as any of those described above or below). As shown, the solidregions 432 can include islands 436. As with any other continuouslocking sheet patterns of the present disclosure, the islands 436 can beconnected to adjacent islands by bridges that extend through the openregions 434; however, for simplicity, the bridges are not shown in FIGS.6A-6C. Furthermore, seven islands 436 are illustrated by way of exampleonly merely for illustration purposes.

As shown by way of example, the surface 425 of each locking sheet 410includes a high friction surface, and particularly, includes a pluralityof engagement features 440. The top locking sheet 410 can be referred toas a first locking sheet 410 having a plurality of first engagementfeatures 440, and the bottom locking sheet 410 can be referred to as asecond locking sheet 410 having a plurality of second engagementfeatures 440 configured to engage the plurality of first engagementfeatures 440. The surfaces 425 are shown by way of example as includingthe high friction surface, i.e., the engagement features 440, across theentire surface 425; however, as described above, this need not be thecase.

The engagement features 440 are shown schematically as having triangularcross-sectional shapes, such that engagement features 440 in one lockingsheet 410 can inter-engage with engagement features 440 in the otherlocking sheet 410. Specifically, the engagement features 440schematically represent engagement features 440 that protrude in the Zdirection toward an adjacent locking sheet 410, such that when thelocking sheets 410 are brought into contact, the engagement features 440from one locking sheet 410 will be moved into the openings or spacesbetween adjacent engagement features 440 in the other locking sheet 410.

The two locking sheets 410 are shown in FIGS. 6A-6C by way of exampleonly; however, it should be understood that one or more solid orpatterned support sheets could be employed in the apparatus 400 insteadof, or in addition to, the two illustrated locking sheets 410. Forexample, in some embodiments, one or both of the illustrated lockingsheets 410 can be solid or patterned support sheets instead, and canstill include the high friction surfaces on the surfaces 425 that can beconfigured to engage the fibrous material 406 and/or an adjacent andopposing support sheet.

While two locking sheets 410 are shown in FIGS. 6A-6C for simplicity, itshould be understood that as many locking sheets 410 as structurallypossible or necessary can be employed in the apparatus 400. In someembodiments, only one locking sheet 410 (or solid or patterned supportsheet) may be necessary to achieve the desired material properties ofthe apparatus 400 in its first state, while providing sufficientinter-engagement within the fibrous material 406 and/or sufficientinter-engagement of the locking sheet 410 (or solid or patterned supportsheet) with the fibrous material 106.

In embodiments employing more than two locking sheets 410 (or solid orpatterned support sheets), two or more locking sheets 410 can eachinclude one or more high friction surfaces (e.g., with engagementfeatures 440) on a surface 425 that is oriented to face the fibrousmaterial 406 and/or another locking sheet 410. In some embodiments, eachlocking sheet 410 (or at least intermediate locking sheets 410 that arepositioned between two adjacent locking sheets 410 or two fibrousmaterials 406) can include two surfaces 425 that are each oriented toface the fibrous material 406 and/or an adjacent locking sheet 410, andeach surface 425 (e.g., a top surface and a bottom surface) can includeone or more high friction surfaces (e.g., with engagement features 440).

The apparatus 400 is shown in FIG. 6A in a first state. In the firststate, the pressure within the chamber 404 can be substantially the sameas the pressure outside the chamber 404, i.e., ambient pressure. Asshown in FIG. 6B, in the first state, the apparatus 400 can be formedinto any desired shape, and the fibrous material 406 and the lockingsheets 410 (e.g., the solid regions 432) can be slidable relative to oneanother and/or movable toward and away from one another (i.e., in a Zdirection that is orthogonal with respect to, or normal to, the lockingsheets 410). As also shown in FIG. 6B, the locking sheets 410, inaddition to the envelope 402, are extensible and formable, due torelative motion between adjacent locking sheets 410, as well as relativemotion between solid regions 432 that can occur within the major surfaceof each locking sheet 410. In addition, the fibrous material 406 isextensible and formable, due to relative motion between fibers, orportions of one or more longer fibers, within the fibrous material 406,as well as relative motion between the fibrous material 406 and any ofthe locking sheets 410 (or other support sheets employed).

After the desired shape has been achieved, the vacuum source 420 can beactivated to evacuate the chamber 404, thereby reducing the pressure inthe chamber 404 to below ambient pressure. As the chamber 404 isevacuated, the locking sheets 410 are forced into contact with oneanother and with the fibrous material 406, volume (or space, air orgaps) within the fibrous material 406 is at least partially decreased,the fibrous material 406 is forced to lock on (or inter-engage with)itself, and the desired shape of the apparatus 400 is essentiallylocked. As shown in FIG. 6C, in embodiments in which the locking sheets410 include high friction surfaces, and particularly, engagementfeatures 440, the engagement features 440 of one locking sheet 410 caninter-engage with the engagement features 440 on another locking sheet410, as described above, and/or with the fibrous material 406. Suchinter-engagement between adjacent locking sheets 410 (and/or with thefibrous material 406) can enhance the stiffness or rigidity of theapparatus 400 in the second state.

As mentioned above, the apparatus 400 can be maintained in the secondstate, as shown in FIG. 6C, for as long as desired by either maintainingthe vacuum pressure via the vacuum source 420, or by sealing the port415 or the connector 422 after the pressure in the chamber 404 has beenreduced.

A method according to one embodiment of the present disclosure will nowbe described with respect to the apparatus 400 of FIGS. 6A-6C. Such amethod can include providing the apparatus 400 in a first state, asshown in FIG. 6A, in which the apparatus 400 is formable, the fibrousmaterial 406 is freely movable, the fibrous material 406 and the lockingsheets 410 are slidable relative to one another, and the solid regions432 of each locking sheet 410, including the islands 436, are movablewithin the major surface of the locking sheet 410 relative to oneanother. In addition, in the first state, any high friction surfaces onsurfaces 425 (e.g., including engagement features 440) of the lockingsheets 410 (or solid or patterned support sheets) that are oriented toface the fibrous material 406 or another locking sheet 410 may move pastthe fibrous material 406 or another high friction surface (e.g.,including engagement features 440) on an adjacent locking sheet 410without inter-engaging or only intermittently engaging.

The method can further include forming the apparatus 400 into a desiredshape (i.e., a three-dimensional shape), as shown in FIG. 6B, whereinthe formability of the apparatus 400 is at least partly facilitated bythe relative motion within the fibrous material 406 and the relativemotion of the solid regions 432 (e.g., the islands 436) in the lockingsheets 410.

As shown in FIG. 6C, the method can further include changing theapparatus 400 from the first, unlocked, state to the second, locked,state by evacuating the chamber 404, for example, by activating thevacuum source 420 to remove gas (e.g., substantially all gas) from thechamber 404 via the port 415 and, optionally, the connector 422.Evacuating the chamber 404 reduces (or eliminates) the volume of (orspace, or air, or gaps within) the fibrous material 406, causes thelocking sheets 410 to be drawn into direct and intimate contact with thefibrous material 406, and optionally (as shown), with one another,thereby increasing the overall stiffness or rigidity of the apparatus400 to essentially lock the apparatus 400 in the desired shape. Thedirect and intimate contact of the locking sheets 410 can also includeinter-engagement of engagement features 440 on adjacent locking sheets410 (e.g., across or through the fibrous material 406), such that theengagement features 440 of adjacent locking sheets 410 are locked withrespect to one another. As mentioned above, however, such locking can bereversible, such that the apparatus 400 can be changed from the secondstate back to the formable first state by releasing the vacuum from thechamber 404 (i.e., allowing the chamber 404 to return to ambientpressure).

FIG. 7 illustrates a shape-formable apparatus 500 according to anotherembodiment of the present disclosure. The apparatus 500 is generallysheet-like or plate-like, or has a sheet-like or plate-likeconfiguration. The shape-formable apparatus 500 includes an envelope 502that defines a chamber 504; fibrous material 506; a plurality of lockingsheets 510 comprising solid regions 532 and open regions 534; and a port(or opening) 515 positioned to fluidly couple the chamber 504 withambience, such that a vacuum source (not shown) can be coupled to theport 515 for evacuating the chamber 504. The difference between theapparatus 500 of FIG. 7 and the apparatus 100 of FIGS. 1A-1C is that theapparatus 500 includes discontinuous locking sheets 510, i.e., includingdiscrete or separate solid regions 532.

As shown in FIG. 7, in some embodiments, the discrete solid regions 532can form “floating” islands that are not connected to one another, andcan be referred to interchangeably as discrete solid regions or floatingislands. In such embodiments, the islands can be coupled to a substrate(or backing) and particularly, an extensible substrate, so that thelocking sheets 510 have significant conformability. In some embodiments,at least a portion of the envelope 502 (e.g., a top or bottom portion orlayer thereof) can provide at least a portion of the substrate for alocking sheet 510. Alternatively, or additionally, the apparatus 500 caninclude an additional material or layer that forms at least a portion ofthe substrate for a locking sheet 510, and such additional material orlayer can be sheet-like or plate-like, and can be positioned in thechamber 504. Such additional substrate materials or layers can be formedof any of the variety of materials described above with respect to theenvelope 102 of FIGS. 1A-1C. In this case, however, the gas permeabilityof the substrate can be high, since it may not comprise the gasimpermeable envelope 502 of the apparatus. In addition, in someembodiments, a solid support sheet, a patterned support sheet, and/or acontinuous locking sheet of the present disclosure can serve as thesubstrate to which a discontinuous locking sheet is coupled.

Similar to FIGS. 1A-1C, FIG. 7 is illustrated for clarity purposes withthe top and bottom sides of the envelope 502 being substantially spacedapart (i.e., with a sidewall joining them), and with the locking sheets510 being substantially spaced apart from one another. However, itshould be understood that this illustration is used merely to better andmore clearly show how the locking sheets 510 can overlap one another andcan be positioned in the chamber 504. In reality, the apparatus 500 canappear much flatter, having a sheet-like or plate-like configuration.

The apparatus 500 of FIG. 7 is shown by way of example only as includingtwo locking sheets 510, each of which includes discrete solid regions532 that are directly coupled to the envelope 502, i.e., an innersurface 505 thereof. However, it should be understood that, as describedabove, in some embodiments, the apparatus 500 can include only one ofthe illustrated locking sheet 510, which can be configured to lock orinter-engage with the fibrous material 506.

As shown, the solid regions 532 of the locking sheets 510 can be coupledto a top inner surface of the envelope 502 to form one locking sheet 510and a bottom inner surface of the envelop 502 to form the other lockingsheet 510, such that the resulting locking sheets 510 can have an atleast partially overlapping and substantially parallel configuration. Insome embodiments, the top inner surface and the bottom inner surface ofthe envelope 502 can be provided by sheets or sheet-like layers that canbe sealed on all sides to provide the sheet-like apparatus 500; howeverother means of forming the sheet-like apparatus 500 are possible.

The solid regions 532 can be coupled to the envelope 502 (and/orsubstrate, if employed) by a variety of coupling means, including, butnot limited to, hook-and-loop fasteners (e.g., irreversible engagementfeatures, such as those employed in interlocking materials availableunder the trade designation 3M™ DUAL LOCK™, 3M Company, St. Paul,Minn.), adhesives, cohesives, clamps, crimps, heat sealing, stitches,pins, staples, screws, nails, rivets, brads, welding (e.g., sonic (e.g.,ultrasonic) welding), any thermal bonding technique (e.g., heat and/orpressure applied to one or both of the components to be coupled), othersuitable coupling means, or combinations thereof.

By way of further example, the top locking sheet 510 shown in FIG. 7includes a plurality of rectangular-shaped islands 532 arranged inhorizontal and vertical rows, with the long side of each rectangularisland 532 oriented in an X direction, and the bottom locking sheet 510includes the same rectangular islands 532 arranged in horizontal andvertical rows, but rotated 90 degrees with respect to the islands 532 ofthe top locking sheet 510, such that the long side of the rectangularislands 532 of the bottom locking sheet 510 have the long side orientedin a Y direction, or a direction that is oriented substantiallyperpendicularly with respect to the long-side direction (X direction) ofthe top locking sheet 510. That is, the apparatus 500 of FIG. 7illustrates one example of adjacent locking sheets 510 (andparticularly, discontinuous locking sheets 510) having patterns that arerotated with respect to one another. In embodiments in which one or bothof the top and bottom locking sheets 510 include high friction surfaces,the rotated patterns can ensure, for example, that one island 532 of thebottom locking sheet 510 will overlap and inter-engage with more thanone island 532 of the top locking sheet 510 (e.g., across or through thefibrous material 506) when the apparatus 500 is in the second state,creating one rigid sheet having a thickness equal to the sum of thethicknesses of the individual locking sheets 510 and the evacuatedfibrous material 506.

The regularly-arranged and rectangular-box-shaped islands 532 in eachlocking sheet 510 (i.e., in rows of uniformly-spaced islands) are shownby way of example only. However, it should be understood that not onlyare other shapes of islands 532 possible, but other arrangements arepossible as well. For example, in some embodiments, the islands 532 canbe disc-shaped, or have another useful shape. Additionally, oralternatively, the islands 532 can be arranged in a different pattern(e.g., a more densely packed pattern), or in a random arrangement. Insome embodiments, each island 532 can be positioned to overlap at leasta portion of an island 532 in an adjacent locking sheet 510, and/or tooverlap fibrous material 506. In addition, each locking sheet 510 neednot include the same sized and shaped islands 532 as in another lockingsheet 510 (if more than one is employed), or have the same or a similarpattern or arrangement. Rather, in some embodiments, two adjacentlocking sheets 510 can have differently shaped, sized and/or arrangedislands 532.

In some embodiments, as shown in FIG. 7, each locking sheet 510 can becoupled to the envelope 502, or in other embodiments, each locking sheet510 can be coupled to an additional substrate. Still, in otherembodiments, the apparatus 500 can include a combination ofdiscontinuous locking sheets 510 that are coupled to the envelope 502and discontinuous locking sheets 510 that are coupled to an additionalsubstrate (e.g., that are located, e.g., stacked, in the space betweenthe two locking sheets 510 shown in FIG. 7).

Furthermore, as mentioned above, in some embodiments, the apparatus 500can include a combination of discontinuous locking sheets 510,continuous locking sheets, and/or one or more solid or patterned supportsheets. For example, one or more continuous locking sheets (or othersolid or patterned support sheets) can be positioned in the chamber 504in the space between the two illustrated discontinuous locking sheets510, i.e., in an at least partially overlapping relationship andsubstantially parallel configuration with one or both of thediscontinuous locking sheets 510 and overlapping relationship with thefibrous material 506, or additional fibrous materials or portions of thefibrous material 506. In such embodiments, by way of example only, theone or more continuous locking sheets (or solid or patterned supportsheets) can include one or more surfaces (i.e., a top surface and/or abottom surface) that are each configured to face an adjacent lockingsheet 510. One or both of these surfaces can include a high frictionsurface that is configured to inter-engage with one of the discontinuouslocking sheets 510. That is, high friction surfaces can be employed inany embodiment of the present disclosure on any surface of a supportsheet (e.g., locking sheet) that is oriented to face fibrous materialand/or another locking sheet.

FIGS. 8A-8C illustrate a shape-formable apparatus 600 according toanother embodiment of the present disclosure, employing fibrous material606, and discontinuous locking sheets 610 comprising discrete solidregions 632, open regions 634, and surfaces 625 configured to face thefibrous material 606 and/or an adjacent locking sheet 610 (and/or othersupport sheet). The apparatus 600 is generally sheet-like or plate-like,or has a sheet-like or plate-like configuration. FIGS. 8A-8C alsoillustrate a method according to one embodiment of the presentdisclosure of using the shape-formable apparatus 600.

The apparatus 600 includes an envelope 602 that defines a chamber 604,fibrous material 606, locking sheets 610, a port 615, a connector 622,and a vacuum source 620 that are each shown schematically merely forpurposes of illustration. For simplicity, only two locking sheets 610are shown, the top locking sheet 610 including four discrete solidregions, or “islands,” 632, and the bottom locking sheet 610 includingfive islands that are staggered with respect to the islands 632 in thetop locking sheets 610, such that when the top and bottom locking sheets610 are brought into direct and intimate contact, the two locking sheets610 inter-engage to essentially form one rigid sheet.

By way of example, each locking sheet 610 is illustrated as beingdirectly coupled to the envelope 602, and particularly, an inner surface605 thereof. Specifically, the top locking sheet 610 is illustrated asbeing coupled to an upper portion or upper inner surface of the envelope602, and the bottom locking sheet 610 is illustrated as being coupled toa bottom portion or lower inner surface of the envelope 602.

The surface 625 of each locking sheet 610 includes a high frictionsurface, and particularly, includes a plurality of engagement features640. The discrete islands 632 of each locking sheet 610 can collectivelydefine the surface 625, and at least a portion of the surface 625 (e.g.,at least a portion of at least some of the islands 632) of each lockingsheet 610 can include the high friction surface. Specifically, eachsurface 625 of the locking sheets 610 includes engagement features 640.

The top locking sheet 610 can be referred to as a first locking sheet610 having a plurality of first engagement features 640, and the bottomlocking sheet 610 can be referred to as a second locking sheet 610having a plurality of second engagement features 640 configured toengage the plurality of first engagement features 640 and/or the fibrousmaterial 606. The surfaces 625 are shown by way of example as includingthe high friction surface, i.e., the engagement features 640, across theentire surface 625; however, as described above, this need not be thecase. The engagement features 640 are shown schematically as havingtriangular cross-sectional shapes, such that engagement features 640 inone locking sheet 610 can inter-engage with engagement features 640 inthe other locking sheet 610. Specifically, the engagement features 640schematically represent engagement features 640 that protrude in the Zdirection toward an adjacent locking sheet 610, such that when thelocking sheets 610 are brought into contact, the engagement features 640from one locking sheet 610 will be moved into the openings or spacesbetween adjacent engagement features 640 in the other locking sheet 610(e.g., across or through the fibrous material 606).

While two locking sheets 610 are shown in FIGS. 8A-8C for simplicity, itshould be understood that as many locking sheets 610 as structurallypossible or necessary can be employed in the apparatus 600. In addition,all of the alternatives mentioned above with respect to FIG. 7 can alsobe employed in the apparatus 600 of FIGS. 8A-8C, including employingonly one locking sheet 610 (or solid or patterned support sheet). Inembodiments employing more than two locking sheets 610, for example, oneor more continuous locking sheets (and/or solid or patterned supportsheets) can be positioned between the two illustrated discontinuouslocking sheets 610. In addition, or alternatively, one or morediscontinuous locking sheets having islands coupled to an additionalsubstrate can be positioned between the two illustrated discontinuouslocking sheets 610.

In addition, in some embodiments employing more than the two illustratedlocking sheets 610, the locking sheets 610 can each include one or morehigh friction surfaces (e.g., with engagement features 640) on a surface625 that is oriented to face another locking sheet 610 and/or thefibrous material 606. In some embodiments, each locking sheet 610 (or atleast intermediate locking sheets 610 that are positioned between twoadjacent locking sheets 610) can include two surfaces 625 that are eachoriented to face an adjacent locking sheet 610 and/or the fibrousmaterial 606, and each surface 625 (e.g., a top surface and a bottomsurface) can include one or more high friction surfaces (e.g., withengagement features 640).

The apparatus 600 is shown in FIG. 8A in a first state. In the firststate, the pressure within the chamber 604 can be the same as thepressure outside the chamber 604, i.e., ambient pressure. As shown inFIG. 8B, in the first state, the apparatus 600 can be formed into anydesired shape, and the fibrous material 606 and the locking sheets 610(e.g., the solid regions 632) can be slidable relative to one anotherand/or movable toward and away from one another (i.e., in a Z directionthat is orthogonal with respect to, or normal to, the locking sheets610) by virtue of the extensibility and conformability of the envelope602. As also shown in FIG. 8B, the locking sheets 610 are extensible andformable, due to the envelope material properties, as well as therelative motion between solid regions 632 that can occur within a majorsurface of each locking sheet 610. In addition, the fibrous material 606is extensible and formable, due to relative motion between fibers, orportions of one or more longer fibers, within the fibrous material 606,as well as relative motion between the fibrous material 606 and any ofthe locking sheets 610 (or other support sheets employed).

After the desired shape has been achieved, the vacuum source 620 can beactivated to evacuate the chamber 604, thereby reducing the pressure inthe chamber 604 to below ambient pressure. As the chamber 604 isevacuated, the locking sheets 610 are forced into contact with oneanother and with the fibrous material 606, volume (or space, air, orgaps) within the fibrous material 606 is at least partially decreased,the fibrous material 606 is forced to lock on (or inter-engage with)itself, and the desired shape of the apparatus 400 is essentiallylocked. As shown in FIG. 8C, in embodiments in which the locking sheets610 include high friction surfaces, and particularly, engagementfeatures 640, the engagement features 640 of one locking sheet 610 caninter-engage with the engagement features 640 on the other locking sheet610, as described above, and/or with the fibrous material 606. Suchinter-engagement between adjacent locking sheets 610 (and/or with thefibrous material 606) can enhance the stiffness or rigidity of theapparatus 600 in the second state.

In addition, as mentioned above, the islands 632 of the top lockingsheet 610 are staggered with respect to the islands 632 of the bottomlocking sheet 610, such that one island 632 of the top locking sheet 610can engage (e.g., inter-engage via mating engagement features 640) twoislands 632 of the bottom locking sheet 610, thereby forming one rigidsheet, and enhancing the resulting stiffness of the apparatus 600 in thesecond state.

As mentioned above, the apparatus 600 can be maintained in the secondstate, as shown in FIG. 8C, for as long as desired by either maintainingthe vacuum pressure via the vacuum source 620, or by sealing the port615 or the connector 622 after the pressure in the chamber 604 has beenreduced.

A method according to one embodiment of the present disclosure will nowbe described with respect to the apparatus 600 of FIGS. 8A-8C. Such amethod can include providing the apparatus 600 in a first state, asshown in FIG. 8A, in which the apparatus 600 is formable, the fibrousmaterial 606 is formable, the fibrous material 606 and the lockingsheets 610 are slidable relative to one another, and the solid regions,or islands, 632 of each locking sheet 610 are movable relative to oneanother (i.e., within a major surface of the respective locking sheet610). In addition, in the first state, any high friction surfaces onsurfaces 625 of the locking sheets 610 (or solid or patterned sheets)that are oriented to face the fibrous material 606 and/or anotherlocking sheet 610 may move past another high friction surface on anadjacent locking sheet 610 without inter-engaging or only intermittentlyengaging.

The method can further include forming the apparatus 600 into a desiredshape (i.e., a three-dimensional shape), as shown in FIG. 8B, where theformability of the apparatus 600 is at least partly facilitated by therelative motion within the fibrous material 606 and the relative motionof the islands 632 in the locking sheets 610 and the material makeup ofthe envelope 602 (or any substrate to which islands are coupled, if notcoupled directly to the envelope 602).

As shown in FIG. 8C, the method can further include changing theapparatus 600 from the first, unlocked, state to the second, locked,state by evacuating the chamber 604, for example, by activating thevacuum source 620 to remove gas (e.g., substantially all gas) from thechamber 604 via the port 615 and, optionally, the connector 622.Evacuating the chamber 604 reduces (or eliminates) the volume of (orspace, or air, or gaps within) the fibrous material 606, causes thelocking sheets 610 to be drawn into direct and intimate contact with thefibrous material 606, and optionally (as shown), with one another,thereby increasing the overall stiffness or rigidity of the apparatus600 to essentially lock the apparatus 600 in the desired shape. Thedirect and intimate contact of the locking sheets 610 can also includeinter-engagement of engagement features 640 on adjacent locking sheets610, such that the engagement features 640 of adjacent locking sheets640 are locked with respect to one another. As mentioned above, however,such locking can be reversible, such that the apparatus 600 can bechanged from the second state back to the formable first state byreleasing the vacuum from the chamber 604 (i.e., allowing the chamber604 to return to ambient pressure).

FIGS. 9A-9B and 10A-10D illustrate apparatuses 700 and 800 according toother embodiments of the present disclosure that employ discontinuouslocking sheets. For simplicity and clarity, the apparatuses 700 and 800are illustrated without any fibrous material, and the description of theapparatuses 700 and 800 below focuses on the features of thediscontinuous locking sheets. However, fibrous material of the presentdisclosure can also be employed in the apparatuses 700 and 800,according to any of the ways in which fibrous material is employed inthe apparatuses of FIGS. 1A-1C, 6A-6C, 7, and 8A-8C, as described above,including any of the alternatives described above. Reference isparticularly made to the description above accompanying FIGS. 7 and8A-8C for a more complete description of how fibrous material can beemployed in the apparatuses 700 and 800. In addition, reference is madeto FIGS. 6A-6C and 8A-8C for a more complete description of a method ofusing the apparatuses 700 and 800 when the apparatuses employ fibrousmaterial.

As mentioned above, FIGS. 9A and 9B illustrate close-up partial views ofan apparatus 700 according to another embodiment of the presentdisclosure. The apparatus 700 is generally sheet-like or plate-like andincludes two discontinuous locking sheets 710.

The apparatus 700 includes an envelope 702 that defines a chamber 704; aplurality of locking sheets 710 comprising discrete solid regions (or“islands”) 732 and open regions 734; and a port (or opening) 715positioned to fluidly couple the chamber 704 with ambience, such that avacuum source (not shown) can be coupled to the port 715 for evacuatingthe chamber 704.

The apparatus 700 includes many of the same elements, features andfunctions as the embodiments of FIGS. 7 and 8A-8C, which also employdiscontinuous locking sheets. Reference is made to the description aboveaccompanying FIGS. 7 and 8A-8C for a more complete description of thefeatures (and alternatives to such elements and features) of thediscontinuous locking sheets of FIGS. 9A and 9B.

The difference between the apparatus 700 of FIGS. 9A and 9B and theapparatus 500 of FIG. 7 is that the discontinuous locking sheets 710 ofFIGS. 9A and 9B include discrete islands 732 that each have a fixed end742 that is directly coupled to an inner surface 705 of the envelope 702(or a substrate), and a free end 744 that extends at least partially ina Z direction toward an adjacent locking sheet 710 and is not directlycoupled to the envelope 702 (or substrate). The fixed ends 742 of theislands 732 can be coupled to the envelope 702 (and/or substrate, ifemployed) by any of the coupling means described above with respect toFIG. 7.

In addition, the free ends 744 of the islands 732 of adjacent lockingsheets 710 are configured to overlap one another (similar to a deck ofcards being shuffled). As a result, each locking sheet 710 stillincludes islands 732 that are movable relative to one another within amajor surface of the locking sheet 710, such that the apparatus 700 canbe formable in a first state. However, the overlapping free ends 744 ofadjacent locking sheets 710 can enhance the intimate contact betweenadjacent locking sheets 710 and the resulting stiffness of the apparatus700, when the apparatus is in the second state. By way of example, insome embodiments, fibrous material can be positioned between the freeends 744 of the islands 732 of adjacent locking sheets 710, e.g., toenhance the friction and intimate contact between adjacent free ends744. In addition, or alternatively, fibrous material can be positionedat least between adjacent free ends 744 of the islands 732 of the samelocking sheet 710. Still, other ways of employing fibrous material inthe apparatus 700 are possible and are within the spirit and scope ofthe present disclosure.

In some embodiments, the islands 732 (or at least the free ends 744thereof) can include a surface 725 oriented to face at least oneadjacent locking sheet 710, e.g., one or more free ends 744 of islands732 in an adjacent locking sheet 710. Such surfaces 725 can include highfriction surfaces, and can include any of the high friction surfacefeatures or alternatives described in embodiments above.

In addition, while the locking sheets 710 are shown as being directlycoupled to the envelope 702, it should be understood that the lockingsheets 710 can instead be coupled to an additional substrate asdescribed above, and/or additional locking sheets 710 can be employed,e.g., intermediately of the two locking sheets 710 shown in FIGS. 9A and9B. For example, in some embodiments, a discontinuous locking sheet canbe employed between the two illustrated locking sheets 710 that includesfloating islands coupled to a top and bottom surface of a substrate.Such islands can include only fixed ends (similar to the locking sheets510 of FIG. 7), and/or can include free ends that are configured tooverlap free ends of the islands of one or both of the illustratedlocking sheets 710.

Furthermore, while only two locking sheets 710 are shown for simplicity,it should be understood that as many locking sheets 710 as structurallypossible or necessary can be employed in the apparatus 700, and the twolocking sheets 710 are merely shown to illustrate the concept of islands732 comprising overlapping free ends 744 that are not directly coupledto the envelope 702 (or other substrate).

For clarity purposes only, the islands 732 having overlapping free ends744 are illustrated in FIGS. 9A-9B as angling away from the fixed ends742, and the top and bottom sides of the of the envelope 702 areillustrated as being substantially spaced apart. However, it should beunderstood that this illustration is used merely to better and moreclearly show how the free ends 744 of the islands 732 can overlap oneanother, and that, in reality, the apparatus 700 can still be sheet-likeor plate-like, and the locking sheets 710 can be considered to beoriented substantially parallel to one another.

While each locking sheet 710 of FIGS. 9A-9B is shown as including onlyone row of islands 732, it should be understood that the locking sheets710 can include as few as one row of islands 732, and as many aspossible or necessary. The envelope 702 can be sized to accommodate morethan one row. In addition, the free ends 744 of the islands 732 areshown as overlapping along one axis or direction (e.g., an X direction).If more than one row is employed, each row can include islands 732 withfree ends 744 that overlap in one axis, and the rows (and the axis ofeach row) can be oriented substantially parallel with respect to oneanother. However, in some embodiments employing more than one row ofislands 732, the islands 732 can be sized and shaped, and coupled to theenvelope 702 (or substrate) accordingly, to allow for the islands tohave free ends 744 that overlap along more than one axis or direction(e.g., in an X direction and a Y direction). Such an embodiment isillustrated in FIGS. 10A-10D and described below.

The islands 732 are shown as having a generally rectangular shape forexample and illustration purposes only. However, it should be understoodthat the same configuration can be employed with any shape of islands732, e.g., including, but not limited to, circles, triangles, squares,trapezoids, any other polygonal shape, irregular or random shapes, othersuitable shapes, or combinations thereof. The islands 732 of one lockingsheet 710 need not all be the same, and rather, in some embodiments, onelocking sheet 710 can include islands 732 of a variety of shapes, sizesand/or materials. In addition, the islands 732 in each locking sheet 710are shown as having the same shape, size, and orientation as in theadjacent locking sheet 710. However, it should be understood thatadjacent locking sheets 710 need not include the islands 732 of the sameshape, size or orientation. For example, in some embodiments, one of thelocking sheets 710 can include square- or circular-shaped islands 732such that only a portion of the free ends 744 of such islands 732overlaps the free ends 744 of the islands 732 in the adjacent lockingsheet 710.

In some embodiments, the apparatus 700 can include a combination of thediscontinuous locking sheets 710, other discontinuous sheets (such asthe discontinuous sheets 510 of FIG. 7), and/or continuous lockingsheets. In such embodiments, for example, the discontinuous lockingsheets can include discrete islands (i.e., with only fixed ends and/orwith fixed and free overlapping ends) coupled to a substrate. Theplurality of locking sheets employed in such embodiments can be arranged(e.g., at least partially stacked) in an at least partially overlappingrelationship and substantially parallel configuration. In addition, insuch embodiments, if a discontinuous locking sheet is employed as anintermediate locking sheet (i.e., having two adjacent locking sheets),the discontinuous locking sheet can include discrete islands coupled toa top surface and a bottom surface of the substrate. In suchembodiments, the islands on either side of the substrate need not besimilarly sized, shaped, and/or arranged. In addition, anyintermediately positioned locking sheet can include two surfaces (e.g.,a top surface and a bottom surface) oriented to face another lockingsheets, and one or both of these surfaces can include a high frictionsurface. That is, high friction surfaces can be employed in anyembodiment of the present disclosure on any surface of a locking sheetthat is oriented to face another locking sheet.

FIGS. 10A-10D illustrate an apparatus 800 according to anotherembodiment of the present disclosure. FIG. 10A shows a perspective viewof one island 832 according to one embodiment of the present disclosure.FIGS. 10B-10D illustrate close-up partial views of an apparatus 800according to another embodiment of the present disclosure that employs aplurality of the islands 832 of FIG. 10A.

The apparatus 800 includes an envelope 802 that defines a chamber 804; aplurality of locking sheets 810 comprising discrete solid regions (or“islands”) 832 and open regions 834; and a port (not shown, removed forclarity) positioned to fluidly couple the chamber 804 with ambience,such that a vacuum source (not shown) can be coupled to the port forevacuating the chamber 804. The apparatus 800 is generally sheet-like orplate-like and includes two discontinuous locking sheets 810 comprisingislands 832 that overlap islands of an adjacent locking sheet 810 alongtwo axes or directions.

With reference to FIG. 10A, the island 832 includes a fixed end 842 anda free end 844 and is configured to overlap islands 832 of an adjacentlocking sheet 810 in two axes or directions, as shown in FIGS. 10B-10Dand described below. By way of example only and for purposes ofillustration, the islands 832 are shown as being formed into thethree-dimensional shape shown in FIG. 10A, having nine connectedplatforms 845 that are all at different levels, or Z axis positions. Byway of further example, the top-most platform 845 a of the island 832 isshown in FIG. 10A as forming the fixed end 842 (i.e., configured to becoupled to an upper inner surface of the envelope 802, or anothersubstrate), while the remaining platforms are included in the free end844. However, it should be understood that the bottom-most platform 845b (i.e., an underside thereof) could instead form the fixed end 842 ofthe island (i.e., by being coupled to a bottom inner surface of theenvelope 802, or another substrate), with the remaining platforms 845included in the free end 844. This would be the case, for example, forislands of a lower or bottom locking sheet 810, as will be described ingreater detail with respect to FIGS. 10B-10D. It should be understoodthat the nine-platform-shaped islands 832 are shown by way of exampleonly for more clearly illustrating how one portion or corner (e.g., thetop-most or bottom-most platform 845) of an island 832 can be coupled tothe envelope 802 (or another substrate), in such a way that the rest ofthe island 832 can form the free end 844 that is configured to extendfrom the fixed end 842 to overlap one or more other islands 832 in twodirections.

The apparatus 800 of FIGS. 10B-10D includes many of the same elements,features and functions as the embodiments of FIGS. 9A-9B, which alsoemploys discontinuous locking sheets 710 that include islands 732 withfree ends 744 that overlap free ends 744 of islands 732 in an adjacentlocking sheet 710. Reference is made to the description aboveaccompanying FIGS. 9A-9B for a more complete description of the features(and alternatives to such elements and features) of the embodiments ofFIGS. 10A-10D.

The difference between the apparatus 800 of FIGS. 10B-10D and theapparatus 700 of FIGS. 9A-9B is that the discrete islands 832 of FIGS.10B-10D have free ends 842 that overlap free ends 844 of islands 832 inan adjacent locking sheet 810 in more than one direction, andparticularly, along two axes (e.g., an X and a Y axis, or direction).Particularly, the apparatus 800 of FIGS. 10B-10D can be understood byimagining that each of the islands 732 of the apparatus 700 of FIGS.9A-9B has been sectioned along its width, and that the free end 744 ofeach island 732 not only overlaps an adjacent free end 744 of anopposing locking sheet 710 along two axes, but also overlaps the freeend 744 of an adjacent island 732 on the same locking sheet 710 alongtwo axes.

With continued reference to FIGS. 10A-10D, the fixed ends 842 of theislands 832 can be directly coupled to an inner surface 805 of theenvelope 802 (or a substrate), and the free ends 844 can extend at leastpartially in a Z direction toward an adjacent locking sheet 810. Suchfree ends 844 are not directly coupled to the envelope 802 (orsubstrate). The fixed ends 842 of the islands 832 can be coupled to theenvelope 802 (and/or substrate, if employed) by any of the couplingmeans described above with respect to FIG. 7.

In FIGS. 10B-10D, cutaway views of a top portion 803 and a bottomportion 803′ of the envelope 802 are shown for clarity, and the topportion 803 of the envelope 802 is cutaway to better illustrate the twolocking sheets 810 and the islands 832. By way of example, the apparatus800 is shown as including a first locking sheet 810 comprising firstislands 832, each first island 832 having a fixed end 842 coupled to thetop portion 803 of the envelope 802 (i.e., an inner surface 805thereof); and a second locking sheet 810′ comprising second islands832′, each second island 832′ having a fixed end 842′ coupled to thebottom portion 803′ of the envelope 802′ (i.e., an inner surface 805′thereof).

All nine platforms 845 of the far right, top first island 832 of thefirst locking sheet 810 are visible in FIGS. 10B and 10C. Particularly,the top-most platform 845 a forms the fixed end 842 that is coupled tothe top portion 803 of the envelope 802, and the remaining platformsform the free end 844 of the island 832. A second island 832′ of thesecond locking sheet 810′ that is overlapped by the first island 832 ofthe first locking sheet 810 includes a bottom-most platform 845 b′(i.e., an underside thereof) that forms the fixed end 842′ of the secondisland 832′ that is coupled to the bottom portion 803′ of the envelope802. This pattern of overlapping first and second islands 832, 832′ isthen continued in the X and Y directions, so that each first island 832of the first locking sheet 810 directly overlaps a second island 832′ ofthe second locking sheet 810′, and the respective free ends 844, 844′ ofthe pair of first and second islands 832, 832′ overlaps a similar pairof islands 832, 832′ in the X direction and the Y direction, and so on,as further shown in FIGS. 10C and 10D. FIGS. 10C and 10D showcross-sectional perspective views to further illustrate how pairs of thefirst and second islands 832, 832′ of the first and second lockingsheets 810, 810′ overlap along two axes.

As with other embodiments discussed above, other shapes, sizes andarrangements of the islands 832 can be employed in the apparatus 800without departing from the present disclosure. In addition, while theislands 832 of the apparatus 800 are shown as all having the same shapeand size, it should be understood that these need not be the case.Furthermore, in some embodiments, the apparatus 800 can include acombination of the discontinuous locking sheets 810 of FIGS. 10B-10D andone or more of (i) fixed-end only discontinuous locking sheets (see,e.g., the islands 532 of FIG. 7); and (ii) continuous locking sheets.Furthermore, in some embodiments, the islands 832 (e.g., the free ends844 thereof) can include one or more surfaces oriented to face anadjacent locking sheet 810, and such surfaces can include high frictionsurfaces, as described above.

FIGS. 11-25 illustrate various embodiments of continuous locking sheetpatterns (i.e., employing continuous solid regions) of the presentdisclosure, wherein like numerals represent like elements. Such lockingsheets can be employed in any of apparatuses of the present disclosure,and can be used in combination with fibrous material within a chamberdefined by an envelope.

FIG. 11 illustrates a locking sheet 910 according to one embodiment ofthe present disclosure. The locking sheet 910 includes solid regions 932and open regions 934. The solid regions 932 include islands 936 havingan octagonal shape, and each island 936 is connected to each adjacentisland 936 by two bridges 938, as described in greater detail below. Thepattern of the locking sheet 910 is similar to the locking sheets 110 ofFIGS. 1 and 4, except that in the locking sheet 910, each islandincludes four sides or edges that are each connected to two bridges 938instead of only one.

As shown in FIG. 11, the islands 936 are arranged in a square-packedarrangement, such that the pattern of the locking sheet 910 includes arepeat unit, or unit cell, that can be propagated in any direction(i.e., left, right, up, down), comprising one central octagonal island936 that is connected to four adjacent islands 936 by eight bridges 938,i.e., two bridges 938 per adjacent island 936. The bridges 938 areequally-spaced about the central island 936, such that every otheroctagonal edge of the central island 936 is connected to two bridges938. By way of example, each bridge 938 includes a 90-degree bend, andeach pair of bridges 938 coming from the same edge of an island 936 bendin opposite directions from one another, i.e., clockwise andcounter-clockwise, such that the open regions 934 include a repeat unitcomprising a substantially square space between four adjacent islands936 that includes four bridges 938 bending toward a center of the squarespace, and such that the pattern of the first locking sheet 910 includes4-fold rotational symmetry about the center of each island 936, inaddition to 4 axes of symmetry.

FIG. 12 illustrates a locking sheet 1010 according to another embodimentof the present disclosure. The locking sheet 1010 includes solid regions1032 and open regions 1034. The solid regions 1032 include islands 1036having a substantially square shape, and each island 1036 is connectedto each adjacent island 1036 by one bridge 1038, respectively. As shownin FIG. 12, the islands 1036 are arranged in a square-packedarrangement, such that the pattern of the locking sheet 1010 includes arepeat unit, or unit cell, comprising four adjacent and connectedislands 1036 arranged in a square. Each island 1036 in FIG. 12 isconnected to four adjacent islands 1036 by four bridges 1038,respectively. For example, a first island 1036 is connected to oneisland 1036 above and one island 1036 below on the same vertical line asthe first island 1036; and the first island 1036 is connected to oneisland 1036 on the left and one island 1036 on the right on the samehorizontal line as the first island 1036. Each bridge 1038 extends fromone edge of the first square island 1036 and has the same width as theedge of the first square island 1036.

By way of example, each bridge 1038 includes two 90-degree bends thatare spaced a greater distance apart than the bends are spaced from anisland 1036, such that the open regions 1034 in the pattern includealternating horizontal and vertical “I” shapes. The pattern of thelocking sheet 1010 includes lines of symmetry along the lengths of the“I”-shaped open regions 1034 oriented horizontally and vertically. Inaddition, the angles of the two 90-degree bends sum to 180 degrees, suchthat a first bend in a bridge 1038 as it extends from an island 1036bends clockwise or counter-clockwise (left or right), and a second bendin the same bridge 1038 bends again in the same direction, i.e.,clockwise or counter-clockwise (left or right), before connecting to theadjacent island 1036.

Each island 1036 has four bridges 1038 extending from it that all bendin the same direction (i.e., clockwise or counter-clockwise). However,each island 1036 has bridges 1038 bending in the opposite direction(i.e., counter-clockwise or clockwise) as that of the bridges 1038extending from one of its connected, adjacent islands 1036.

FIG. 13 illustrates a locking sheet 1110 according to another embodimentof the present disclosure. The locking sheet 1110 includes solid regions1132 and open regions 1134. The solid regions 1132 include islands 1136having a substantially square shape, and each island 1136 is connectedto each adjacent island 1136 by one bridge 1138, respectively. Thepattern shown in FIG. 13 is substantially the same as that of FIG. 12,except that the relative sizing of islands 1136 to bridges 1138 has beenchanged. Particularly, the width of each bridge 1138 of the lockingsheets 1110 of FIG. 13 is substantially less than an edge of each island1136. In addition, each bridge 1138 is positioned to extend from an edgeof an island 1136, directly adjacent one of the corners of the squareisland 1136. As a result, the tops and bottoms of thevertically-oriented “I”-shaped open regions 1134 are positioned closerto the long middle segments of the horizontally-oriented “I”-shaped openregions 1134, and the tops and bottoms of the horizontally-oriented“I”-shaped open regions 1134 are positioned closer to the long middlesegments of the vertically-oriented “I”-shaped open regions 1134.

FIG. 14 illustrates a locking sheet 1210 according to another embodimentof the present disclosure. The locking sheet 1210 includes solid regions1232 and open regions 1234. The solid regions 1232 include islands 1236having a substantially square shape, and each island 1236 is connectedto each adjacent island 1236 by one bridge 1238, respectively. As shownin FIG. 14, the islands 1236 are arranged in a square-packedarrangement, such that the pattern of the locking sheet 1210 includes arepeat unit, or unit cell, comprising one island 1236 and a portion ofits four bridges 1238 extending therefrom to adjacent islands 1236. Eachisland 1236 in FIG. 14 is connected to four adjacent islands 1236 byfour bridges 1238, respectively. For example, a first island 1236 isconnected to one island 1236 above and one island 1236 below; and thefirst island 1236 is further connected to one island 1236 on its leftand one island 1236 on its right. Each bridge 1238 has a width that issubstantially less than the width of one side or edge of the island 1236and extends from a side of the island 1236 directly adjacent a corner ofthe square island 1236.

By way of example, each bridge 1238 includes eight 90-degree bends, thefirst four bends all going in the same direction (i.e., clockwise) tospiral outwardly around the island 1236 from which it extends, thesecond four bends all going in the opposite direction (i.e.,counter-clockwise) to spiral inwardly around and to an adjacent island1236. As a result, the lengths of a bridge 1238 between its adjacentbends progressively increase around the island 1236 from which itextends, while the lengths of the bridge 1238 between its adjacent bendsprogressively decrease around the adjacent islands 1236 to which itextends and connects.

FIG. 15 illustrates a locking sheet 1310 according to another embodimentof the present disclosure. The locking sheet 1310 includes solid regions1332 and open regions 1334. The solid regions 1332 include islands 1336having a substantially square shape, and each island 1336 is connectedto each adjacent island 1336 by one bridge 1338, respectively. As shownin FIG. 15, the islands 1336 are arranged in a square-packedarrangement, such that the pattern of the locking sheet 1310 includes arepeat unit, or unit cell, comprising one island 1336 and a portion ofits four bridges 1338 extending therefrom to adjacent islands 1336. Eachisland 1336 in FIG. 15 is connected to four adjacent islands 1336 byfour bridges 1338, respectively. For example, a first island 1336 isconnected to one island 1336 above and one island 1336 below; and thefirst island 1336 is further connected to one island 1336 on its leftand one island 1336 on its right. Each bridge 1338 has a width that issubstantially less than the width of one side or edge of the island 1336and extends from a side of the island 1336 directly adjacent a corner ofthe square island 1336.

By way of example, each bridge 1338 includes ten 90-degree bends; or afirst 90-degree bend, followed by four 180-degree bends to essentiallyzig-zag outwardly from a side of one island 1336 toward a side of anadjacent island 1336, followed by a final 90-degree bend to connect tothe adjacent island 1336. The first 90-degree bend coming from each sideof a given island 1336 turns in the same direction (i.e., clockwise, orright), and the final 90-degree bend into an adjacent island 1336 turnsin the opposite direction (i.e., counter-clockwise, or left). Thelengths between adjacent bends of a bridge 1338 progressively increase,as the bridge 1338 zig-zags to a position that is about midway betweentwo adjacent islands 1336, and then progressively decrease toward theadjacent island 1336.

FIG. 16 illustrates a locking sheet 1410 according to another embodimentof the present disclosure. The locking sheet 1410 includes solid regions1432 and open regions 1434. The solid regions 1432 include islands 1436having a substantially square shape, and each island 1436 is connectedto each adjacent island 1436 by one bridge 1438, respectively. Thepattern shown in FIG. 16 is substantially the same as that of FIG. 15,except for the following: (i) the scale of FIG. 16 is different fromFIG. 15; the islands 1436 and bridges 1438 of FIG. 16 are larger, suchthat the locking sheet 1410 of FIG. 16 includes fewer islands 1436 perarea; (ii) each bridge 1438 includes fourteen 90-degree bends; or afirst 90-degree bend, followed by six 180-degree bends to essentiallyzig-zag outwardly from a side of one island 1436 toward a side of anadjacent island 1436, followed by a final 90-degree bend to connect tothe adjacent island 1436; and (iii) the first 90-degree bend coming fromeach side of a given island 1436 turns counter-clockwise (or left), andthe final 90-degree bend into an adjacent island 1436 turns in theopposite direction, i.e., clockwise, or right).

FIG. 17 illustrates a locking sheet 1510 according to another embodimentof the present disclosure. The locking sheet 1510 includes solid regions1532 and open regions 1534. The solid regions 1532 include islands 1536,and each island 1536 is connected to each adjacent island 1536 by onebridge 1538, respectively. The pattern shown in FIG. 17 is substantiallythe same as that of FIG. 16, except for the following: (i) the islands1536 have a substantially rectangular (or elongated parallelogram)shape; (ii) each bridge 1538 includes six 90-degree bends; or a first90-degree bend, followed by two 180-degree bends to zig-zag outwardlyfrom a side of one island 1536 toward a side of an adjacent island 1536,followed by a final 90-degree bend to connect to the adjacent island1536; (iii) the lengths between adjacent bends of a bridge 1538extending from a long side of an island 1536 are all approximately thesame as one another and do not progressively increase and then decreaselike they do on the short side of the island 1536; and (iv) the spacing(i.e., the open regions 1534) between the islands 1536 and bridges 1538of FIG. 17 is narrower.

FIG. 18 illustrates a locking sheet 1610 according to another embodimentof the present disclosure. The locking sheet 1610 includes solid regions1632 and open regions 1634. The solid regions 1632 include islands 1636having a substantially rectangular (or elongated parallelogram) shape,and each island 1636 is connected to each adjacent island 1636 by onebridge 1638, respectively. The pattern shown in FIG. 18 is substantiallythe same as that of FIG. 15, except for the following: (i) the islands1536 have a substantially rectangular (or elongated parallelogram)shape; and (ii) the spacing (i.e., the open regions 1634) between theislands 1636 and bridges 1638 of FIG. 18 is narrower.

FIG. 19 illustrates a locking sheet 1710 according to another embodimentof the present disclosure. The locking sheet 1710 includes solid regions1732 and open regions 1734. The solid regions 1732 include islands 1736having the shape of an equilateral triangle, and each island 1736 isconnected to each adjacent island 1736 by one bridge 1738, respectively.The open regions 1734 include six-legged asterisk- or star-shapedcutouts that are densely packed, such that each leg of oneasterisk-shaped open region 1734 substantially overlaps a leg of anadjacent asterisk-shaped open region 1734.

As shown in FIG. 19, the islands 1736 are arranged in ahexagonally-packed arrangement, such that the pattern of the lockingsheet 1710 includes a repeat unit, or unit cell, comprising sixtriangular islands 1736 arranged into a hexagon and a portion of thebridges 1738 extending therefrom to adjacent islands 1736. Each island1736 in FIG. 19 is connected to three adjacent islands 1736 by threebridges 1738, respectively. For example, a first island 1736 isconnected to one island 1736 above or below, one island 1736 on oneside, and another island 1736 on the other side. Each bridge 1738 has awidth that is substantially less than the width of one side or edge ofthe island 1736 and extends from a side of the island 1736 directlyadjacent a corner of the triangular island 1736.

By way of example, each bridge 1738 includes an immediate first60-degree bend and a second 60-degree bend to connect to another island1736, and the length of the bridge 1738 between the two 60-degree bendsis about equal to one side of a triangular island 1736, such that eachbridge 1738, between the two 60-degree bends, runs along and between aside of a first island 1736 and a side of a second, adjacent, island1736. The first 60-degree bend in each bridge 1738 coming from an island1736 turns in the same direction (i.e., clockwise, or right), and thesecond 60-degree bend into an adjacent island 1736 turns in the oppositedirection (i.e., counter-clockwise, or left).

FIG. 20 illustrates a locking sheet 1810 according to another embodimentof the present disclosure. The locking sheet 1810 includes solid regions1832 and open regions 1834. The solid regions 1832 include islands 1836,and each island 1836 is connected to each adjacent island 1836 by onebridge 1838, respectively. The pattern shown in FIG. 20 is substantiallythe same as that of FIG. 19, except that each bridge 1838 includes four60-degree bends, such that each side of an island 1836 is separated froma side of an adjacent island 1836 by three bridges 1838, and the lengthsof a bridge 1838 between adjacent bends increase as the bridge 1838extends around an island 1836 to a position where the bridge 1838 runsbetween the two adjacent islands 1836 it connects, and then decrease asthe bridge 1838 extends around and connects to a side of the adjacentisland 1836. In addition, each leg of the six-legged asterisk-shapedopen regions 1834 includes a pronged end that is bent at 60 degrees withrespect to the leg from which it extends.

FIG. 21 illustrates a locking sheet 1910 according to another embodimentof the present disclosure. The locking sheet 1910 includes solid regions1932 and open regions 1934. The solid regions 1932 include islands 1936,and each island 1936 is connected to each adjacent island 1936 by onebridge 1938, respectively. The pattern shown in FIG. 21 is substantiallythe same as that of FIGS. 19 and 20, except that each bridge 1938includes six 60-degree bends, with the first three bends bending in thesame direction (i.e., clockwise) around the island 1936 from which thebridge 1938 extends, and the second three bends bending in the oppositedirection (i.e., counter-clockwise) around an adjacent island 1936. Eachside of an island 1936 is separated from a side of an adjacent island1936 by five bends (or portions of a bridge 1938), and the lengths of abridge 1938 between adjacent bends increase as the bridge 1938 extendsaround an island 1936 to a position where the bridge 1938 runs betweenthe two adjacent islands 1936 it connects, and then decrease as thebridge 1938 extends around and connects to a side of the adjacent island1936.

FIG. 22 illustrates a locking sheet 2010 according to another embodimentof the present disclosure. The locking sheet 2010 includes solid regions2032 and open regions 2034. The solid regions 2032 include islands 2036,and each island 2036 is connected to each adjacent island 2036 by onebridge 2038, respectively. The pattern shown in FIG. 22 is substantiallythe same as that of FIG. 20, except that the width of each bridge is thesame as the width of each side of the triangular island 2036 (and theislands 2036 are less obviously triangular in shape). As a result, theasterisk-shaped open regions 2034 are smaller, the legs of theasterisk-shaped open regions 2034 are wider, the legs of oneasterisk-shaped open region 2034 are spaced further from the legs ofadjacent open regions 2034, and the legs only partially overlap those ofadjacent open regions 2034.

FIG. 23 illustrates a locking sheet 2110 according to another embodimentof the present disclosure. The locking sheet 2110 includes solid regions2132 and open regions 2134. The solid regions 2132 include islands 2136,and each island 2136 is connected to each adjacent island 2136 by onebridge 2138, respectively. The pattern shown in FIG. 23 is substantiallythe same as that of FIG. 22, except that each bridge 2138 includes four60-degree bends, such that each side of an island 2136 is separated froma side of an adjacent island 2136 by three bridges 2138, and the lengthsof a bridge 2138 between adjacent bends increase as the bridge 2138extends around an island 1836 to a position where the bridge 2138 runsbetween the two adjacent islands 2136 it connects, and then decrease asthe bridge 2138 extends around and connects to a side of the adjacentisland 2136. In addition, each leg of the six-legged asterisk-shapedopen regions 2134 includes a pronged end that is bent at 60 degrees withrespect to the leg from which it extends.

FIG. 24 illustrates a locking sheet 2210 according to another embodimentof the present disclosure. The locking sheet 2210 includes solid regions2232 and open regions 2234. The solid regions 2232 include islands 2236,and each island 2236 is connected to each adjacent island 2236 by onebridge 2238, respectively. The pattern shown in FIG. 24 is substantiallythe same as that of FIG. 23, except that the asterisk-shaped openregions 2234 are more densely packed, such that each leg of oneasterisk-shaped open region 2234 substantially overlaps a leg of anadjacent asterisk-shaped open region 2234. As a result, the islands 2234of FIG. 24 are smaller than those of FIG. 23, and the bridges 2238 ofFIG. 24 are narrower than those of FIG. 23.

FIG. 25 illustrates a locking sheet 2310 according to another embodimentof the present disclosure. The locking sheet 2310 includes solid regions2332 and open regions 2334. The solid regions 2332 include islands 2336,and each island 2336 is connected to each adjacent island 2336 by onebridge 2338, respectively. Each individual island 2336 has trapezoidalshape (particularly, an elongated trapezoidal shape with two longersides and two short sides), and is connected to four adjacent islands2336 by four bridges 2338, respectively. Particularly, one bridge 2338extends from each side or edge of each island 2336, directly adjacent acorner of the island 2336, and immediately turning to extend alongside(while also being integral with) the side of the island 2336 from whichthe bridge 2338 extends. The pattern of the locking sheet 2310 furtherincludes a plurality of island clusters or groups 2337, each cluster2337 comprising three trapezoidal islands 2336 arranged to form agenerally triangular shape, and particularly, arranged such that theshorter long side of each trapezoidal island 2336 is oriented to face ashort side of an adjacent island 2336 within the same cluster 2337. Sixtriangular clusters 2337 of islands 2336 are arranged about a center toform a generally hexagonal repeat unit, or unit cell, for the pattern ofthe locking sheet 2310. As a result, the island clusters 2337 arearranged in a hexagonally-packed arrangement.

Each island 2336 has four bridges 2338, as mentioned above:

-   -   (i) a first bridge 2338 a that extends from a first short side        of the trapezoidal island 2336 and includes a clockwise        120-degree bend, followed by a clockwise 60-degree bend,        followed by a counter-clockwise 60-degree bend, and followed by        a counter-clockwise 60-degree bend to connect to an adjacent        island 2336;    -   (ii) a second bridge 2338 b that extends from the longest side        of the island 2336 and includes a clockwise 60-degree bend,        followed by a clockwise 60-degree bend, followed by a        counter-clockwise 60-degree end, and followed by        counter-clockwise 120 degree bend to connect to an adjacent        island 2336;    -   (iii) a third bridge 2338 c that extends from a second short        side of the island 2336 and includes a clockwise 60-degree bend,        followed by a clockwise 120-degree bend, followed by a        counter-clockwise 120-degree bend, and followed by        counter-clockwise 120-degree bend to connect to an adjacent        island 2336; and    -   (iv) a fourth bridge 2338 d that extends outwardly from the        shorter of the long sides and includes a clockwise 120-degree        bend, after which the fourth bridge 2338 d is not connected to        the island 2336 but extends adjacent the shorter long side,        followed by a clockwise 120-degree bend, followed by a        counter-clockwise 120-degree bend, and followed a        counter-clockwise 60 degree bend to connect to an adjacent        island 2336.

The locking sheet patterns of FIGS. 11-25 are shown by way of exampleonly; however, it should be understood that other suitable patterns canalso be employed in the locking sheets of the present disclosure. Inaddition, the relative sizing (i.e., aspect ratios), spacing, etc. ofany of the patterns of FIGS. 11-25 can be changed from exactly what isshown without departing from the spirit and scope of the presentdisclosure.

Furthermore, each embodiment of the shape-formable apparatuses shown inthe figures is illustrated as a separate embodiment for clarity inillustrating a variety of features of the shape-formable apparatuses ofthe present disclosure. However, it should be understood that anycombination of elements and features of any of the embodimentsillustrated in the figures and described herein can be employed in theshape-formable apparatuses of the present disclosure. For example, anyof the description of the features and elements (and alternatives tosuch features and elements) of the shape-formable apparatus 100 of FIGS.1A-1C, 4 and 5 (e.g., regarding material makeup of the envelope 102, thefibrous material 106, or the locking sheets 110, the methods of makingthe envelope 102, the fibrous material 106, or the locking sheets 110,various configurations or arrangements of the fibrous material 106 andthe locking sheets 110, or any other detail) can be applied to theembodiments of FIGS. 2-3 and 6A-10D. In addition, any of the lockingpatterns of FIGS. 11-25 can be employed in any shape-formable apparatusembodiment of the present disclosure.

The following embodiments are intended to be illustrative of the presentdisclosure and not limiting.

Embodiments

1. A shape-formable apparatus comprising:

-   -   a first state in which the apparatus is formable, such that the        apparatus can be formed into a desired shape;    -   a second state in which the apparatus has the desired shape and        is substantially less formable than in the first state;    -   an envelope defining a chamber, the envelope formed of a        gas-impermeable material;    -   a port positioned to fluidly couple the chamber with ambience;        and    -   a fibrous material positioned in the chamber, wherein the        fibrous material is substantially less formable when the        apparatus is in the second state than when the apparatus is in        the first state.

2. The apparatus of embodiment 1, wherein the fibrous material comprisesat least one fiber, and wherein the at least one fiber has an aspectratio of at least 10.

3. The apparatus of embodiment 1 or 2, wherein the fibrous materialincludes a nonwoven.

4. The apparatus of any of embodiments 1-3, wherein the fibrous materialincludes a bundle of fibers.

5. The apparatus of any of embodiments 1-4, wherein the fibrous materialincludes at least one of:

-   -   a fiber having portions movable relative to one another within        the fibrous material, at least when the apparatus is in the        first state, and    -   a plurality of fibers that are movable relative to one another        within the fibrous material, at least when the apparatus is in        the first state.

6. The apparatus of any of embodiments 1-5, wherein the fibrous materialis formed of at least one of a metal, a polymeric material, a ceramic, acomposite material, and a combination thereof.

7. The apparatus of any of embodiments 1-6, further comprising a supportsheet positioned adjacent the fibrous material in the chamber.

8. The apparatus of embodiment 7, wherein the support sheet includes asolid sheet.

9. The apparatus of embodiment 7 or 8, wherein the support sheetincludes an annealed metal.

10. The apparatus of any of embodiments 7-9, wherein the support sheetincludes a patterned sheet that includes one or more indentations.

11. The apparatus of any of embodiments 7-10, wherein the support sheetincludes a locking sheet comprising a major surface, and wherein atleast a portion of the locking sheet is patterned to include solidregions and open regions, the solid regions being movable with respectto one another within the major surface.

12. The apparatus of embodiment 11, wherein the solid regions aremovable with respect to one another within the major surface from afirst position to a second position that can be maintained after anapplied force is removed, without plastic deformation.

13. The apparatus of embodiment 11 or 12, wherein the solid regions areformed of a material having an effective tensile modulus (E_(o)), andwherein the solid regions and open regions are arranged in the lockingsheet such that the locking sheet has an overall effective tensilemodulus (E₁), and wherein the ratio of E_(o)/E₁ for the locking sheet isat least 2.

14. The apparatus of any of embodiments 11-13, wherein the locking sheetincludes a surface oriented to face at least one of the fibrous materialand another support sheet, and wherein the surface includes a highfriction surface.

15. The apparatus of any of embodiments 11-14, wherein the locking sheetincludes continuous solid regions.

16. The apparatus of any of embodiments 11-15, wherein the locking sheetincludes discrete solid regions.

17. The apparatus of embodiment 16, wherein at least one discrete solidregion includes a fixed end coupled to a substrate and a free end thatis not coupled to the substrate.

18. The apparatus of any of embodiments 1-17, further comprising atleast two support sheets positioned in an at least partially overlappingand at least partially coplanar configuration, wherein at least aportion of the fibrous material is positioned between two adjacentsupport sheets.

19. The apparatus of embodiment 18, wherein the at least two supportsheets are oriented substantially parallel with respect to one another.

20. The apparatus of embodiment 18 or 19, wherein the at least twosupport sheets include a first support sheet and a second support sheetthat are configured to inter-engage.

21. The apparatus of any of embodiments 18-20, wherein at least onesupport sheet includes a solid sheet.

22. The apparatus of any of embodiments 18-21, wherein at least onesupport sheet includes an annealed metal.

23. The apparatus of any of embodiments 18-22, wherein at least onesupport sheet includes a patterned sheet that includes one or moreindentations.

24. The apparatus of any of embodiments 18-23, wherein at least onesupport sheet includes a locking sheet comprising a major surface, andwherein at least a portion of the locking sheet is patterned to includesolid regions and open regions, the solid regions being movable withrespect to one another within the major surface.

25. The apparatus of embodiment 24, wherein the solid regions of thelocking sheet are formed of a material having an effective tensilemodulus (E_(o)), and wherein the solid regions and open regions arearranged in the locking sheet such that each locking sheet has anoverall effective tensile modulus (E₁), and wherein the ratio ofE_(o)/E₁ for the locking sheet is at least 2.

26. The apparatus of embodiment 24 and 25, wherein the locking sheetincludes a surface oriented to face at least one of the fibrous materialand another support sheet, and wherein the surface includes a highfriction surface.

27. The apparatus of any of embodiments 1-26, wherein the envelope isformed of at least one of polydimethylsiloxane, liquid silicone rubber,poly(styrene-butadiene-styrene), and a combination thereof.

28. The apparatus of any of embodiments 1-27, wherein the chamber isevacuated in the second state, relative to the first state.

29. The apparatus of any of embodiments 1-28, wherein the apparatus hasa first stiffness in the first state and a second stiffness in thesecond state, and wherein the stiffness ratio of the second stiffness tothe first stiffness is at least 2.

30. The apparatus of any of embodiments 1-29, wherein the apparatus hasa first effective tensile modulus (E_(UL)) when in the first state and asecond effective tensile modulus (E_(L)) when in the second state, andwherein the ratio of the second modulus to the first modulus(E_(L)/E_(UL)) is at least 2.

31. The apparatus of any of embodiments 1-30, wherein the apparatus hasa first effective bending modulus (B_(UL)) when in the first state and asecond effective bending modulus (B_(L)) when in the second state, andwherein the ratio of the second modulus to the first modulus(B_(L)/B_(UL)) is at least 2.

32. The apparatus of any of embodiments 1-31, wherein the apparatus hasa first effective indentation modulus (I_(UL)) when in the first stateand a second effective indentation modulus (I_(L)) when in the secondstate, and wherein the ratio of the second modulus to the first modulus(I_(L)/I_(UL)) is at least 2.

33. The apparatus of any of embodiments 1-32, wherein the apparatus isconfigured to substantially conform to a complex surface having anon-zero Gaussian curvature when the apparatus is in the first state.

34. The apparatus of any of embodiments 1-33, wherein the apparatus issheet-like.

35. The apparatus of any of embodiments 1-34, wherein the apparatus hasa first ratio of thickness to a first surface dimension and a secondratio of thickness to a second surface dimension, and wherein the firstratio and the second ratio are each less than 0.1.

36. The apparatus of any of embodiments 1-35, wherein the envelopeincludes a low friction outer surface.

37. The apparatus of any of embodiments 1-36, wherein the envelope isformed of at least one of silicon, polydimethylsiloxane, liquid siliconerubber, poly(styrene-butadiene-styrene), and a combination thereof.

38. The apparatus of any of embodiments 1-37, wherein the port isconfigured to be coupled to a vacuum source.

39. The apparatus of any of embodiments 1-38, wherein the fibrousmaterial is one of a plurality of fibrous materials positioned in thechamber.

It is to be understood that the invention is not limited in itsapplication to the details of construction and the arrangement ofcomponents set forth in the above description or illustrated in theaccompanying drawings. The invention is capable of other embodiments andof being practiced or of being carried out in various ways. Also, it isto be understood that the phraseology and terminology used herein is forthe purpose of description and should not be regarded as limiting. It isto be further understood that other embodiments may be utilized, andstructural or logical changes may be made without departing from thescope of the present disclosure.

The following working examples are intended to be illustrative of thepresent disclosure and not limiting.

EXAMPLES Example 1—Shape-Formable Apparatus (without Fibrous Material;Locking Sheets Only)—Assembly

With reference to FIGS. 1B and 1C (without the fibrous material 106B and106C), three shape-formable apparatuses 100 were assembled in the mannerdescribed below. The following description refers generically to thereference numerals of FIGS. 1B and 1C, i.e., without the “B” and “C”designations in the reference numerals. Twenty locking sheets 110 of11.43 cm (4.5 in)×11.43 cm (4.5 in)×9.7E-2 cm (3.8E-3 in) 20 lb. paperobtained from Staples, Inc. of Framingham, Mass. were placed on top ofone another in an overlapping stack where the solid regions 132 and openregions 134 of the locking sheets 110 were aligned with one another.Each of the twenty sheets was patterned to match the design representedand described in FIG. 15. The stack of twenty locking sheets 110 wasthen placed into a 1.27E-2 cm (5.0E-3 in) thick polyurethane envelope102 obtained from Lubrizol Corp. of Wickliffe, Ohio and sealed with anAIE-100T Impulse Hand Sealer obtained from American InternationalElectric of City of Industry, CA. A port 115 was inserted through thepolyurethane envelope 102 prior to sealing.

Three additional shape-formable apparatuses 100 were assembledidentically to the procedure defined above with the exception that thetwenty sheets were not patterned.

To change the state of the shape-formable apparatuses 100 from unlocked(formable) to locked (rigid), a DOA-P704-AA oilless diaphragm vacuumpump obtained from Gast of Benton Harbor, Mich. was connected to theport 115 through a connector 122 obtained from McMaster-Carr ofElmhurst, Ill. The vacuum source 120 was activated and the pressurewithin the envelope 102 was reduced to approximately −78 kPa to changethe state of the shape-formable apparatuses 100 from formable to rigid.The vacuum source 120 was maintained to keep the apparatuses in thelocked condition (i.e., second state).

Example 2—Shape-Formable Apparatus (without Fibrous Material; LockingSheets Only)—Performance

The six shape-formable apparatuses 100 assembled in Example 1 weresubjected to three tests to determine their effective tensile, bending,and indentation moduli while in the formable (unlocked) and rigid(locked) states. The shape-formable apparatuses 100 were characterizedvia the following test procedures.

Test Procedures Effective Tensile Modulus

Effective Tensile Modulus was measured by placing the shape-formableapparatus 100 into a LF Plus Digital Material Tester obtained fromAmetek Measurement & Calibration Technologies (formerly LloydInstruments) of Largo, Fla. Two opposite ends of the shape-formableapparatuses 100 were clamped into the LF Plus Digital Material Testerwith rubber faced manual operated vice grips also obtained from AmetekMeasurement & Calibration Technologies (formerly Lloyd Instruments) ofLargo, Fla. Each of the three formable (unlocked) shape-formableapparatuses 100 were tested three times and the average values of theforce exerted per distance (N/mm) extended were recorded. Each of thethree rigid (locked) shape-formable apparatuses 100 were tested threetimes and the average values of the force exerted per distance (N/mm)extended were recorded as measured tension, T_(measured).

The Effective Tensile Modulus (i.e., for rectangular specimens) isdefined as the Force per unit width divided by strain:

${ETM} = {\frac{{Force}\mspace{14mu} {per}\mspace{14mu} {unit}\mspace{14mu} {width}}{strain} = {\frac{\frac{F}{W}}{\frac{\Delta \; L}{L}} = {\left( \frac{F}{\Delta \; L} \right){\left( \frac{L}{W} \right).}}}}$

The procedure described above measures the force divided by extension,

$T_{measured} = {\frac{F}{\Delta \; L}.}$

The Effective Tensile Modulus was calculated from the measured tension,T_(measured), by multiplying by the length and dividing by the width ofthe sample,

${ETM} = {{T_{measured}\left( \frac{L}{W} \right)}.}$

Effective Bending Modulus

Measurement of the Effective Bending Modulus was performed by clampingone end of the shape-formable apparatus 100 with a rubber faced manualoperated vice grip obtained from Ametek Measurement & CalibrationTechnologies (formerly Lloyd Instruments) of Largo, Fla. The other endof the shape-formable apparatus 100 was oriented straight down (alignedwith gravity) and clamped with a binder clip. The binder clip wasattached to a cable composed of fishing line obtained from Shimano Corp.of Irvine, Calif. through a pulley, such that the binder clip was pulledorthogonal to gravity, and attached to the LF Plus Digital MaterialTester obtained from Ametek Measurement & Calibration Technologies(formerly Lloyd Instruments) of Largo, Fla., to measure the deflectiondistance, x. Each of the three formable (unlocked) shape-formableapparatuses 100 were tested three times and the average values of thebending force per distance bent (or deflected) (N/mm) were recorded.Each of the three rigid (locked) shape-formable apparatuses 100 weretested three times and the average values of the force exerted perdistance bent (or deflected) (N/mm) were recorded as measured bending,B_(measured).

The Effective Bending Modulus is defined as the Force per unit widthdivided by the angle of deflection:

${EBM} = {\frac{{Force}\mspace{14mu} {per}\mspace{14mu} {unit}\mspace{14mu} {width}}{theta} = {\frac{\frac{F}{W}}{\theta}.}}$

The angle of deflection can be approximated (small angle approximation)as θ˜x/L, which implies that

${{EBM} = {\frac{\frac{F}{W}}{\frac{x}{L}} = {\left( \frac{F}{x} \right)\left( \frac{L}{W} \right)}}},$

were x is the deflection distance. The procedure described abovemeasures the force divided by the deflection distance,

$B_{measured} = {\frac{F}{x}.}$

The Effective Bending Modulus was calculated from the measured Bending,B_(measured), by multiplying by the length and dividing by the width ofthe sample,

${EBM} = {{B_{measured}\left( \frac{L}{W} \right)}.}$

Effective Indentation Modulus

Indentation stiffness was performed by placing the shape-formableapparatus 100 on a ring support structure. The shape-formable apparatus100 was free to slide across the surface of the ring support structure.The inner diameter of the ring support structure was 2.40 in (6.10 cm).The center of the shape-formable apparatus 100 was pushed or indentedwith a LF Plus Digital Material Tester obtained from Ametek Measurement& Calibration Technologies (formerly Lloyd Instruments) of Largo, Fla.The diameter of the tip that pushed on the apparatus was 0.63 in (1.60cm). Each of the three formable (unlocked) shape-formable apparatuses100 were tested three times and the average values of the indentationforce per distance indented (N/mm) were recorded. Each of the threerigid (locked) shape-formable apparatuses 100 were tested three timesand the average values of the force exerted per distance (N/mm) extendedwere recorded.

The Effective Indentation Modulus is defined as the force applied to thesample divided by the deflection distance:

${EIM} = {\frac{{Force}\mspace{14mu} {applied}}{{deflection}\mspace{14mu} {distance}} = {\frac{F}{x}.}}$

This is the direct measurement that is made by the procedure above, sono calculation was necessary.

Results of the tests are summarized in Table 1. Ratios of the averagelocked stiffness as compared to the average unlocked stiffness for eachof the tests were also computed and are recorded in Table 1.

In addition, the polyurethane envelope 102 used in the examples wastested by itself according to the Effective Tensile Modulus methoddescribed above, and was found to have an Effective Tensile Modulus of1.21 N/mm.

TABLE 1 ETM, EBM and EIM for locked and unlocked apparatuses includingunpatterned solid sheets and patterned locking sheets. Paper, 20 sheets,Solid sheets Paper, 20 sheets, Locking sheets Locked Unlocked LockedUnlocked (L) (UL) Ratio (L) (UL) Ratio [N/mm] [N/mm] [L/UL] [N/mm][N/mm] [L/UL] ETM 3738 3824 1.0 70.1 4.3 [E_(a)] 16.1 EBM 0.056 0.003814.5 0.0067 0.0016 4.2 EIM 13.2 5.9 2.2 8.0 0.97 8.2

This data shows that the solid paper cannot be easily extended, limitingits conformability, while the patterned paper (i.e., locking sheet) isabout 1000 times easier to extend. A significant ratio in thelocked/unlocked extensibility with the patterned paper was observed,versus no measurable change for the unpatterned paper (i.e., solidsheet). The indentation ratio was also better with the patterned paper.Significant wrinkling was also seen in the indentation test of the solid(i.e., unpatterned) paper.

Example 3—ETM Performance of Locking Sheets Vs. Solid Sheets (withoutFibrous Material)

Six sets of sheets were assembled with the following characteristics;(1) a stack of 20 unpatterned (i.e., solid) paper sheets, (2) a stack of20 sheets of paper cut with the pattern of FIG. 15 with a laser cutter(Model No. ILS 9.75, available from Universal Laser System, Scottsdale,Ariz.) (3) 1 sheet of unpatterned 0.005″ thick annealed aluminum, (4) 1sheet of 0.005″ thick annealed aluminum patterned via water jet cuttingwith the pattern shown in FIG. 15, (5) 2 sheets of 1/16″ thickunpatterned Delrin, and (6) 2 sheets of 1/16″ Delrin cut with thepattern of FIG. 15. The Effective Tensile Modulus of all six sets ofsheets was tested according to the procedure in Example 2. The resultsof the testing are summarized below in Table 2.

TABLE 2 ETM for patterned locking sheets and unpatterned (solid) sheets.Patterned ETM Unpatterned ETM Ratio Material [E₁, N/mm] [E_(o), N/mm][E_(o)/E₁] 1 Sheet Paper (.003″) 0.0022 24.5 10,947 1 Sheet Delrin(.063″) 2.7 1,868 692 1 Sheet Aluminum (.005″) 0.87 2,375 2,448

In addition, the overall ETM for an unlocked apparatus (Ea) comprising20 sheets of patterned paper was reported in Table 1 as 4.3 (N/mm), andthe ETM for unpatterned paper (Eo) was reported in Table 2 as 24.5, sothe ratio of Eo/Ea for an apparatus comprising 20 patterned paperlocking sheets is (24.5/4.3) about 6.

Example 4—Shape-Formable Apparatus (Fibrous Material Only)

Two shape-formable apparatuses 100 were assembled. A mat of fibrousmaterial was placed inside the envelope in place of the locking sheetsand assembled according to the procedure of Example 1. Two types offibrous material were used: 1) Steel Wool [grade 4 extra course steelwool from McMaster Carr], and 2) Fiber Glass [2 layers cut from a bat ofFrost King ¾″ thick Multi-Purpose Fiberglass Insulation]. Theapparatuses were subjected to the three tests of Example 2 to determinetheir effective tensile, bending, and indentation moduli, while in theunlocked and locked states (i.e., without and with vacuum). The ETM, EBMand EIM were calculated and are summarized in Table 4.

TABLE 4 ETM, EBM and EIM for locked and unlocked apparatuses includingfibrous materials. Steel Wool Fiberglass Locked Unlocked Locked Unlocked(L) (UL) Ratio (L) (UL) Ratio [N/mm] [N/mm] [L/UL] [N/mm] [N/mm] [L/UL]ETM 15.36 3.06 5.0 91.35 9.9 9.2 EBM 0.0298 0.00394 7.6 0.0085 0.00312.7 EIM 2.43 0.484 5.0 3.42 0.33 10.5

Example 5—Shape-Formable Apparatus (Fibrous Material and Support Sheet)

A shape-formable apparatus 100 was assembled. A mat of Steel Wool [grade4 extra course steel wool from McMaster Carr] surrounded on both sidesby a 0.005″ thick annealed aluminum sheet [1100 series; Yield Strength2,500 psi; Soft (23 Brinell)] was placed inside the envelope in place ofthe locking sheets and assembled according to the procedure ofExample 1. The finished construction was similar to FIG. 1B with solid(i.e., unpatterned) support sheets instead of locking sheets. Theapparatus was subjected to the EBM and EIM tests of Example 2 todetermine the effective bending and indentation moduli, while in theunlocked and locked states (i.e., without and with vacuum). The EBM andEIM were calculated and are summarized in Table 5.

TABLE 5 EBM and EIM for locked and unlocked apparatuses including steelwool and solid annealed aluminum support sheets. Steel Wool + AluminumSupport Sheets Locked (L) Unlocked (UL) Ratio [N/mm] [N/mm] [L/UL] EBM0.036 0.0060 5.9 EIM 8.89 1.77 5.0

Example 6—Shape-Formable Apparatus (Fibrous Material and Locking Sheet)

A shape-formable apparatus 100 was assembled. A mat of Steel Wool [grade4 extra course steel wool from McMaster Carr], surrounded on both sidesby a 0.062″ thick delrin locking sheet, patterned according to thepattern of FIG. 15, was placed inside the envelope in place of thelocking sheets and assembled according to the procedure of Example 1.The finished construction was similar to FIG. 1B. The apparatus wassubjected to the three tests of Example 2 to determine the effectivetensile, bending, and indentation moduli, while in the unlocked andlocked states (i.e., without and with vacuum). The ETM, EBM and EIM werecalculated and are summarized in Table 6.

TABLE 6 ETM, EBM and EIM for locked and unlocked apparatuses includingsteel wool and delrin locking sheets. Steel Wool + Delrin Locking SheetsLocked (L) Unlocked (UL) Ratio [N/mm] [N/mm] [L/UL] ETM 66.45 6.97 9.5EBM 0.024 0.016 1.5 EIM 5.33 2.49 2.1

All references and publications cited herein are expressly incorporatedherein by reference in their entirety into this disclosure.

Various features and aspects of the present disclosure are set forth inthe following claims.

1. A shape-formable apparatus comprising: a first state in which theapparatus is formable, such that the apparatus can be formed into adesired shape; a second state in which the apparatus has the desiredshape and is substantially less formable than in the first state; anenvelope defining a chamber, the envelope formed of a gas-impermeablematerial; a port positioned to fluidly couple the chamber with ambience;and a fibrous material positioned in the chamber, wherein the fibrousmaterial is substantially less formable when the apparatus is in thesecond state than when the apparatus is in the first state.
 2. Theapparatus of claim 1, wherein the fibrous material comprises at leastone fiber, and wherein the at least one fiber has an aspect ratio of atleast
 10. 3. The apparatus of claim 1, wherein the fibrous materialincludes at least one of a nonwoven and a bundle of fibers.
 4. Theapparatus of claim 1, wherein the fibrous material includes at least oneof: a fiber having portions movable relative to one another within thefibrous material, at least when the apparatus is in the first state, anda plurality of fibers that are movable relative to one another withinthe fibrous material, at least when the apparatus is in the first state.5. The apparatus of claim 1, further comprising a support sheetpositioned adjacent the fibrous material in the chamber.
 6. Theapparatus of claim 5, wherein the support sheet includes at least one ofa solid sheet, and a patterned sheet comprising one or moreindentations.
 7. The apparatus of claim 5, wherein the support sheetincludes an annealed metal.
 8. The apparatus of claim 5, wherein thesupport sheet includes a locking sheet comprising a major surface, andwherein at least a portion of the locking sheet is patterned to includesolid regions and open regions, the solid regions being movable withrespect to one another within the major surface.
 9. The apparatus ofclaim 8, wherein the solid regions are movable with respect to oneanother within the major surface from a first position to a secondposition that can be maintained after an applied force is removed,without plastic deformation.
 10. The apparatus of claim 8, wherein thesolid regions are formed of a material having an effective tensilemodulus (E_(o)), and wherein the solid regions and open regions arearranged in the locking sheet such that the locking sheet has an overalleffective tensile modulus (E₁), and wherein the ratio of E_(o)/E₁ forthe locking sheet is at least
 2. 11. The apparatus of claim 8, whereinthe locking sheet includes continuous solid regions.
 12. The apparatusof claim 8, wherein the locking sheet includes discrete solid regions.13. The apparatus of claim 12, wherein at least one discrete solidregion includes a fixed end coupled to a substrate and a free end thatis not coupled to the substrate.
 14. The apparatus of claim 1, furthercomprising at least two support sheets positioned in an at leastpartially overlapping and at least partially coplanar configuration,wherein at least a portion of the fibrous material is positioned betweentwo adjacent support sheets.
 15. The apparatus of claim 14, wherein theat least two support sheets are oriented substantially parallel withrespect to one another.
 16. The apparatus of claim 1, wherein theapparatus has a first effective tensile modulus (E_(UL)) when in thefirst state and a second effective tensile modulus (E_(L)) when in thesecond state, and wherein the ratio of the second modulus to the firstmodulus (E_(L)/E_(UL)) is at least
 2. 17. The apparatus of claim 1,wherein the apparatus has a first effective bending modulus (B_(UL))when in the first state and a second effective bending modulus (B_(L))when in the second state, and wherein the ratio of the second modulus tothe first modulus (B_(L)/B_(UL)) is at least
 2. 18. The apparatus ofclaim 1, wherein the apparatus has a first effective indentation modulus(I_(UL)) when in the first state and a second effective indentationmodulus (I_(L)) when in the second state, and wherein the ratio of thesecond modulus to the first modulus (I_(L)/I_(UL)) is at least
 2. 19.The apparatus of claim 1, wherein the apparatus is configured tosubstantially conform to a complex surface having a non-zero Gaussiancurvature when the apparatus is in the first state.
 20. The apparatus ofclaim 1, wherein the apparatus is sheet-like.